Tool Run-Out Measurement in Micro Milling

Attanasio, Aldo

doi:10.3390/mi8070221

Cited by 40 publications

(28 citation statements)

References 38 publications

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“…A force measurement and data acquisition system that consists of a piezoelectric 3-component force sensor (Kistler 9317C) connected to charge amplifiers (Kistler 5015A) which receives three charge signals proportional to the cutting force as input and returns amplified voltage signals as output was used. This force measuring system accuracy is approximately equal to 0.1 N [12] which is sufficient for capturing forces in micro milling.…”

Section: Experimental Approachmentioning

confidence: 97%

“…In the recent decades, a large number of publications are dedicated to understand micro milling processes. These are mainly concerned with miniature machine tool development, process modeling to achieve a greater understanding about cutting force generation and mechanistic modeling [6][7][8][9], chatter vibrations [10], workpiece defects and surface quality, tool edge effects [11], tool run-out effects [12,13], thermal stability [14], and many other issues. Last several years, researchers also dealt with the possibility of implementing predictive process models with finite element (FE) simulations [13,[15][16][17][18], a useful capability to refine the knowledge about force generation and chip formation in micro milling.…”

Section: Introductionmentioning

confidence: 99%

“…At this length scale, ploughing, size effect, burr formation, rapid tool wear, higher than expected cutting forces, and tool run-out cannot be neglected being the most common micro milling related issues [3,[20][21][22]. Among all of these issues in micro milling process, tool run-out is certainly the most important issue causing geometrical inaccuracies, workpiece defects, and burr formation and deserves more attention [12,13,20,21,23]. This phenomenon occurs due to the sum of the geometrical displacements of the tool axis, the spindle axis, and the tool-holder axis from the ideal axis of rotation [12].…”

Section: Introductionmentioning

confidence: 99%

“…Among all of these issues in micro milling process, tool run-out is certainly the most important issue causing geometrical inaccuracies, workpiece defects, and burr formation and deserves more attention [12,13,20,21,23]. This phenomenon occurs due to the sum of the geometrical displacements of the tool axis, the spindle axis, and the tool-holder axis from the ideal axis of rotation [12]. The ratio between this offset and the feed per tooth could be easily high in high speed micro milling (typically rotational speeds that are higher than 10,000 rev/ min and up to 100,000 rev/min).…”

Section: Introductionmentioning

confidence: 99%

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Finite element simulation of high speed micro milling in the presence of tool run-out with experimental validations

Attanasio

Abeni

Özel

et al. 2018

Int J Adv Manuf Technol

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Micro milling process of CuZn37 brass is considered important due to applications in tool production for micro moulding and micro replication technology. The variations in material properties, work material adhesion to tool surfaces, burr formation, and tool wear result in loss of productivity. The deformed chip shapes together with localized temperature, plastic strain, and cutting forces during micro milling process can be predicted using finite element (FE) modeling and simulation. However, toolworkpiece engagement suffers from tool run-out affecting process performance in surface generation. This work provides experimental investigations on effects of tool run-out as well as process insight obtained from simulation of chip flow, with and without considering tool run-out. Scanning electron microscope (SEM) observation of the 3D chip shapes demonstrates ductile deformed surfaces together with localized serration behavior. FE simulations are utilized to investigate the effects of micro milling operation, cutting speed, and feed rate on forces, chip flow, and shapes. Predicted cutting forces and chip flow results from simulations are compared with force measurements, tool run-out, and chip morphology revealing reasonable agreements.

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Section: Experimental Approachmentioning

confidence: 97%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Finite element simulation of high speed micro milling in the presence of tool run-out with experimental validations

Attanasio

Abeni

Özel

et al. 2018

Int J Adv Manuf Technol

Self Cite

View full text Add to dashboard Cite

show abstract

“…Machining, particularly the micro-nano fabrication technique, plays a crucial role in modern high-tech industry [ 1 , 2 ]. With the rapid development of micro-machine tool manufacturing techniques and cutting-edge grinding techniques, the micro-cutting process has been widely used in the fabrication of components with surface-forming accuracy in the nanoscale [ 3 , 4 ].…”

Section: Introductionmentioning

confidence: 99%

Dislocation Dynamics-Based Modeling and Simulations of Subsurface Damages Microstructure of Orthogonal Cutting of Titanium Alloy

Bai

Tong

2017

Micromachines

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In this work, a novel method is put forward to quantitatively simulate the subsurface damages microstructural alteration of titanium alloy components subjected to microscale cutting. A trans-scale numerical framework is conducted with the purpose of revealing the underlying influence mechanism of tool structure parameters on subsurface dislocation configurations using a dislocation dynamics-based model, which considers both dislocation structural transformation and grain refining. Results showed that the developed framework not only captured the essential features of workpiece microstructure, but also predicted the subsurface damages layer states and their modifications. A series of defects were found in the material subsurface during the orthogonal cutting of titanium alloy, such as edge and screw dislocations, junctions, parallel slip lines, intersection dislocation bands, vacancy defects, and refinement grains. Particularly, in the process of micro-cutting, the depth of subsurface damages layer increased significantly with cutting length at the beginning, and then remained unchanged in the stable removal phase. Moreover, smaller edge radius and larger rake angle can greatly weaken the squeezing action and heat diffusion effect between the tool tip and workpiece, which further prevents the formation of subsurface defects and enhances finished surface quality. In addition, although increasing tool clearance angle could drastically lighten the thickness of subsurface damages layer, it is noteworthy that its performance would be decreased significantly when the clearance angle was greater than or equal to 5°. The micro-end-milling experiment was performed to validate the existing simulation results, and the results show very good agreement.

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