Investigation on dynamic tool deflection and runout-dependent analysis of the micro-milling process

Wang, Dongqian; Penter, Lars; Hänel, Albrecht; Yang, Yang; Ihlenfeldt, Steffen

doi:10.1016/j.ymssp.2022.109282

Cited by 9 publications

(4 citation statements)

References 42 publications

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“…In fact, tool runout may occur in the radial and axial directions due to the complex cutting conditions during micro-milling. The tool runout with the runout distance and runout angle in radial directions has been one of the research hotspots in recent years [10,12,13], without considering the tool runout in the axial direction. Moreover, the regenerative chatter in radial directions has been investigated without considering the vibration in the axial direction in recent research [7,8].…”

Section: Equations Of Cutting Forces Considering Tool Runout Distance...mentioning

confidence: 99%

“…The established model contains the influence of tool runout, geometry, and forced vibration on the effective engagement condition of the tool and workpiece. Wang et al [13] obtained the milling force model by combining the tool eccentricity distance with the runout angle. The papers mentioned above mainly focus on modeling the cutting forces with tool runout; as such, they do not involve the centrifugal force and gyroscopic effect.…”

Section: Introductionmentioning

confidence: 99%

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Dynamic Modeling for Chatter Analysis in Micro-Milling by Integrating Effects of Centrifugal Force, Gyroscopic Moment, and Tool Runout

Liu,

et al. 2024

Micromachines

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During micro-milling, regenerative chatter will decrease the machining accuracy, destabilize the micro-milling process, shorten the life of the micro-mill, and increase machining failures. Establishing a mathematical model of chatter vibration is essential to suppressing the adverse impact of chatter. The mathematical model must include the dynamic motions of the cutting system with the spindle–holder–tool assembly and tool runout. In this study, an integrated model was developed by considering the centrifugal force induced by rotational speeds, the gyroscopic effect introduced by high speeds, and the tool runout caused by uncertain factors. The tool-tip frequency-response functions (FRFs) obtained by theoretical calculations and the results predicted by simulation experiments were compared to verify the developed model. And stability lobe diagrams (SLDs) and time-domain responses are depicted and analyzed. Furthermore, experiments on tool-tip FRFs and micro-milling were conducted. The results validate the effectiveness of the integrated model, which can calculate the tool-tip FRFs, SLDs, and time responses to analyze chatter stability by considering the centrifugal force, gyroscopic effect, and tool runout.

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Section: Equations Of Cutting Forces Considering Tool Runout Distance...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Dynamic Modeling for Chatter Analysis in Micro-Milling by Integrating Effects of Centrifugal Force, Gyroscopic Moment, and Tool Runout

Liu,

et al. 2024

Micromachines

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“…Micro-milling vibration monitoring is a hot technology for enterprises to improve their equipment competitiveness and a frontier and difficult point in modern science and technology academic research [ 17 , 18 , 19 ]. Laser displacement sensors [ 9 , 13 , 14 , 20 ], microphones [ 21 ], capacitance sensors [ 22 ], acceleration sensors [ 23 ], and three-dimensional force sensors [ 24 , 25 , 26 , 27 ] are often used by researchers to obtain machining state signals or use multi-sensor information fusion based on the combining of some of these sensors to predict the tool vibration state [ 9 , 20 , 22 ]. However, there are some problems when the laser displacement sensor is used for the measurements of micro-milling vibration, such as when the spot is larger than the surface area of the tooltip and the sensor needs to be installed far away from the tool system [ 28 ].…”

Section: Introductionmentioning

confidence: 99%

Three-Dimensional Displacement Measurement of Micro-Milling Tool Based on Fiber Array Encoding

Jia

Zhang

2023

Micromachines

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The vibration of the micro-milling tool presents a significant chaotic vibration phenomenon, which has a great influence on the tool life and part machining precision, and is one of the basic problems restricting the improvement of machining efficiency and machining accuracy in micro-milling. To overcome the difficulty of the traditional vibration measurement method with the online measurement of micro-milling tool multi-dimensional vibration, a three-dimensional (3D) measurement method of the micro-milling tool is proposed based on multi-fiber array coding, which converts the tool space motion into a decoding process of the optical coding array employing the tool modulating the multi-fiber array encoding. A 6 × 6 optical fiber array was designed, and a 3D motion platform for micro-milling tools was built to verify the characteristics of the optical fiber measurement system. The measurement results show that the measuring accuracy of the system reached 1 µm, and the maximum linear error in x-, y-, and z-direction are 1.5%, 2.58%, and 2.43%, respectively; the tool space motion position measurement results show that the maximum measurement error of the measuring system was 3.4%. The designed system has unique coding characteristics for the tool position in the space of 100 µm3. It provides a new idea and realization means for the online vibration measurement of micro-milling tools.

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“…Wimmer et al [7] and Wang et al [8] took the effects of tool deflection and runout into accounts on the instantaneous uncut chip thickness and incorporated it with the milling force. Li et al [9] constructed a new model for calculating the instantaneous cutting thickness of micro-milling by integrating the cutting motion trajectory of the tool tip, radial tool runout and jump angle of tool, and then established a force prediction model.…”

Section: Introductionmentioning

confidence: 99%

Stability prediction of micro-milling with tool runout and centrifugal force via using FEM and time-domain formulation

Liu,

Du,

Liu

et al. 2023

Ninth International Conference on Mechanical Engineering, Materials, and Automation Technology (MMEAT 2023)

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Micro-milling is one of important methods for producing miniature components with high-accuracy. During the cutting process, the chatter vibration which can result in instability and poor surface finish may considerably be disturbed by the unpredictable tool runout and centrifugal force with ultra high speeds of micro-mill. This paper tries to develop a time domain dynamic model for depicting chatter vibration of micro-mill with the concerns of tool runout incorporated in cutting forces and centrifugal force included in external force work via combing FEM and time-domain formulation. Several simulations carried out illustrates the validity of the proposed model from the perspectives of FRF, SLD and time domain response.

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Investigation on dynamic tool deflection and runout-dependent analysis of the micro-milling process

Cited by 9 publications

References 42 publications

Dynamic Modeling for Chatter Analysis in Micro-Milling by Integrating Effects of Centrifugal Force, Gyroscopic Moment, and Tool Runout

Dynamic Modeling for Chatter Analysis in Micro-Milling by Integrating Effects of Centrifugal Force, Gyroscopic Moment, and Tool Runout

Three-Dimensional Displacement Measurement of Micro-Milling Tool Based on Fiber Array Encoding

Stability prediction of micro-milling with tool runout and centrifugal force via using FEM and time-domain formulation

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