Fourier analysis for micro-end-milling mechanics

Kang, Yaw-Hong; Zheng, C. M.

doi:10.1016/j.ijmecsci.2012.09.008

Cited by 11 publications

(3 citation statements)

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“…An experimental and FEM modelling approach was proposed to study the micro-milling process under a pre-stress. Ti-6Al-4V samples were selected with a dimension of 10×8×6 mm 3 for the proposed work. The full immersion micro-milling (i.e., undeformed chip thickness varied from zero to feed per tooth of cutter) was performed to cut the slot of 1.5 mm in length and 500 μm in width on the micro-machining centre (KERN microtechnik).…”

Section: Methodsmentioning

confidence: 99%

“…The parameters which are used to characterise a milling process are cutting speed, undeformed chip thickness, axial depth of cut, chip thickness and feed. Kang and Zheng [3] proposed the Fourier series based mathematical models to predict the chip thickness and cutting forces during the micro-milling process including the shearing and the ploughing effect. Jing et al [4] proposed a theoretical model to predict the undeformed chip thickness and elastic recovery during the micro end milling process.…”

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confidence: 99%

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Effects of tailored residual stress on micro-end milling: numerical modelling and validation

Yadav

Chakladar

Paul

2023

Int J Adv Manuf Technol

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Precision components often require micro-milling, where burrs may occur as surface defects. Such defects are likely to be influenced by the stress state in the raw material prior to micro-milling. A pre-treatment on the surface is found to compensate for the formation of burrs and improve the finishing of the micro-milled component. A finite element model of the micromilling process was developed in Abaqus. An enhanced flow algorithm based on straingradient and dynamic recrystallization was used, along with a tool/workpiece friction model.This study revealed that compressive residual stress of about 613 MPa in Ti-6Al-4V can lower burr formation by up to 60%, cutting temperatures by 7% and contact forces by 15%.Additionally, surface residual stresses induced by micro-milling are predicted for compressively pre-stressed and as-received samples. The mechanism of burr formation, cutting forces, and cut marks on the sidewall surface were reported. The simulated burr morphology, chip contact length, cutting forces and surface residual stresses after micro-milling were verified with experimental results.

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Section: Methodsmentioning

confidence: 99%

mentioning

confidence: 99%

Effects of tailored residual stress on micro-end milling: numerical modelling and validation

Yadav

Chakladar

Paul

2023

Int J Adv Manuf Technol

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“…3–12 A number of investigations have focused on the continuous structure for macro-machining operation. 13–16 For micro-machining operation, most of the researchers modeled the tool using classical continuum theory, 17–24 and some few others developed the tool model by applying non-classical continuum theory. 25,26…”

Section: Introductionmentioning

confidence: 99%

Optimization of different parameters related to milling tools to maximize the allowable cutting depth for chatter-free machining

Mokhtari

Jalili

Mazidi

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Determination of optimal parameters of cutting tool is one of the most significant factors in any operation planning of metal elements, especially in micro-milling process. This article presents an optimization procedure, based on genetic algorithms, to optimize some parameters related to micro-milling tool including number of teeth, shank diameter, fluted section diameter, shank length, taper length, and length of fluted section. The aim of this optimization is maximizing the minimum value of cutting depth on the border of stability lobe diagrams, which is called allowable cutting depth, for chatter-free machining. Cutting tool is modeled as a three-dimensional spinning cantilever Timoshenko beam based on strain gradient elasticity theory. Structural nonlinearity, gyroscopic moment, rotary inertia, and velocity-dependent process damping are also considered in the cutting tool model. The values of natural frequency, damping ratio, and material length scale of the micro-milling tool are calculated using a system identification based on genetic algorithm to match the analytical response with recorded experimental vibration signal. Using beam model, the allowable cutting depth is increased in the optimization process for a specific range of spindle speed to avoid the chatter phenomenon. Analytical study of micro-milling process stability is carried out to determine the cost function of the genetic algorithm. A plot of the greatest fitness in each generation is sketched. In addition, stability lobe diagrams before and after optimization process are presented to show the efficiency of the optimized micro-milling tool. In the presented examples, the results of genetic algorithm may lead to design or find a micro-milling tool that its acceptable cutting depth increases up to 1.9313 times.

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Micro Milling

Kuram¹,

Özçelik²

2014

Materials Forming, Machining and Tribology

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Fourier analysis for micro-end-milling mechanics

Cited by 11 publications

References 10 publications

Effects of tailored residual stress on micro-end milling: numerical modelling and validation

Effects of tailored residual stress on micro-end milling: numerical modelling and validation

Optimization of different parameters related to milling tools to maximize the allowable cutting depth for chatter-free machining

Micro Milling

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