On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part I: Surface Generation

Vogler, Michael P.; DeVor, Richard E.; Kapoor, Shiv Gopal

doi:10.1115/1.1813470

Cited by 261 publications

(169 citation statements)

References 19 publications

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“…Liu et al [37] established an analytical model for predicting minimum chip thickness; this model is based on the thermo-mechanical properties of the machined material, which include cutting temperature, strain, and strain rate. Vogler et al [38,39] used finite element modeling approach to investigate the minimum chip thickness of steel; they found that the minimum chip thickness is approximately 0.2 and 0.3 times of the edge radius of a cutting tool for pearlite and ferrite, respectively. This finding validates the assumption that material property affects minimum chip thickness.…”

Section: Micro-cuttingmentioning

confidence: 99%

Recent advances in micro- and nano-machining technologies

Gao

Huang

2017

Front. Mech. Eng.

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Device miniaturization is an emerging advanced technology in the 21st century. The miniaturization of devices in different fields requires production of micro-and nano-scale components. The features of these components range from the sub-micron to a few hundred microns with high tolerance to many engineering materials. These fields mainly include optics, electronics, medicine, bio-technology, communications, and avionics. This paper reviewed the recent advances in micro-and nano-machining technologies, including micro-cutting, micro-electrical-discharge machining, laser micro-machining, and focused ion beam machining. The four machining technologies were also compared in terms of machining efficiency, workpiece materials being machined, minimum feature size, maximum aspect ratio, and surface finish.

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Section: Micro-cuttingmentioning

confidence: 99%

Recent advances in micro- and nano-machining technologies

Gao

Huang

2017

Front. Mech. Eng.

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“…Cutting edge radius (sharpness) and its effect on other parameters such as forces [21,22], surface roughness [22][23][24], burr formation [25] and acoustic emissions (AE) [26] have also been studied. This literature supports the relevancy of this parameter to guarantee a complete chip formation and to predict other process responses.…”

Section: Size Effectmentioning

confidence: 99%

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Giraldo¹,

Serje²,

Bolívar³

et al. 2017

DYNA

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Micro-machining of different polymer based components often require high precision and excellent surface quality at high production rates with low costs. Micro-milling is a cost-efficient micro-machining process capable of generating complex shapes in a wide range of materials. Challenges based on size effect, burr formation and adequate chip removal must be faced and are addressed in this research. Material removal mechanisms, as well as its impact on burr formation and control are reviewed, followed by a case study through the application of gaseous cooling based on vortex tubes. Different vortex generator configurations were tested, proving to be fast response an economically-friendly alternative for burr reduction while micro-milling biopolymers. Configurations, as mentioned above, were used for biopolymer micro-milling towards burr measurement after each test; achieving as a result, a burr reduction while cooling temperature decreases.Keywords: Micro-milling; Burr; Polymer machining; Vortex cooling.Formación de rebabas y su control para el micro-fresado de polímeros: Un caso de estudio con refrigeración por tubo vortex Resumen El micro-maquinado de diferentes componentes basados en polímeros a menudo requiere de gran precisión y un excelente acabado superficial a unas tasas elevadas de producción con un bajo costo. El micro-fresado es un proceso costo-efectivo de micro-maquinado capaz de generar formas complejas en una amplia variedad de materiales. Retos basados en el efecto tamaño, formación de rebabas y una adecuada remoción de la viruta deben ser enfrentados y son tratados en la presente investigación. Los mecanismos de remoción de material, al igual que su impacto en la formación de rebabas y su control, son revisados, acompañados de un caso de estudio a través de la aplicación de refrigeración gaseosa basada en tubos vortex. Diferentes configuraciones de generadores de vortex son probados, demostrando ser una alternativa de respuesta rápida, económica y amigable para la reducción de rebabas mientras se micro-fresan biopolímeros. Dichas configuraciones se utilizaron en el micro-mecanizado de un polímero bio-compatible, midiendo el tamaño de rebaba que se genera en cada prueba, dando como resultado la disminución de estas a media que baja la temperatura de refrigeración.Palabras clave: Micro-fresado; Rebaba; Maquinado de polímeros; Refrigeración con tubo vortex.

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“…In this first case, the box 4 output is a scalar. On the other hand, when considering the effective rake angle (WE approach),  WE is proportional to α eff and their relationship can be found by means of a regression analysis, as done in [24,33] (box 4, WE approach, in Fig. 8).…”

Section: Box 4 -Shear Angle (Second Step)mentioning

confidence: 99%

“…Moreover, the authors took into account the dead metal cap presence and introduced the effective rake angle in the model as a function of the uncut chip thickness [33].…”

mentioning

confidence: 99%

Applicability of an orthogonal cutting slip-line field model for the microscale

Rebaioli

Biella

Annoni

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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Mechanical micromachining is a very flexible and widely exploited process, but its knowledge should still be improved since several incompletely explained phenomena play a role on the microscale chip removal (e.g. "minimum chip thickness effect", microstructure influence on cutting forces, stable built-up edge, etc.). Several models have been developed to describe the machining process, but only some of them take into account a rounded-edge tool, which is a typical condition in micromachining. Among these models, the slip-line field model developed by Waldorf for the macroscale allows to separately evaluate shearing and ploughing force components in orthogonal cutting conditions, therefore it is suitable to predict cutting forces when a large ploughing action occurs, as in micromachining. The present study aims at demonstrating how this model is suitable also for micromachining conditions. In order to achieve this goal, a clear, modular and repeatable procedure has been developed for objectively validating its cutting and feed force prediction performance at low uncut chip thickness (less than 50 µm) and relatively higher cutting edge radius. The proposed procedure makes the model generally applicable after a suitable and 2 non-extensive calibration campaign. The present paper shows how calibration experiments can be selected among the available database of cutting trials basing on the model force prediction capability. Final validation experiments have been used to show how the model is robust to a cutting speed variation even if the cutting speed is not among the model quantities. A suitable set-up, especially designed for microturning conditions, has been used in this research to measure forces and chip thickness. Tests have been carried out on 6082-T6 Aluminum alloy with different cutting speeds and different ratios between uncut chip thickness and cutting edge radius.

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On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part I: Surface Generation

Cited by 261 publications

References 19 publications

Recent advances in micro- and nano-machining technologies

Recent advances in micro- and nano-machining technologies

Burr formation and control for polymers micro-milling: A case study with vortex tube cooling

Applicability of an orthogonal cutting slip-line field model for the microscale

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