Prediction of cutting forces and instantaneous tool deflection in micro end milling by considering tool run-out

Zhang, Xuewei; Yu, Tianbiao; Wang, Wanshan

doi:10.1016/j.ijmecsci.2017.12.019

Cited by 65 publications

(25 citation statements)

References 24 publications

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“…Lu et al [93] then developed a new method for predicting micro-milling tool breakage based on theoretical models by examining the tool bending stress. Finally, Zhang et al [94] formulated a mechanistic model of cutting forces and instantaneous tool deflection in the micro end milling process, which took into account the minimum UCT effect and tooth trajectory. Their model also considered tool runout, consisting of both axial and tilt offsets, including entry and exit angles of the tool.…”

Section: Tool Deflectionmentioning

confidence: 99%

Precision micro-milling process: state of the art

2020

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Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

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Section: Tool Deflectionmentioning

confidence: 99%

Precision micro-milling process: state of the art

2020

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“…T. M. Moges et al [ 3 ] performed an analytical investigation on machining accuracy, considering cutter runout and elastic recovery in micro end milling, and D. Goto et al [ 4 ] focused on tool runout for their experimental studies on machining accuracy. Moreover, some papers have proposed the use of analytical cutting force models [ 5 , 6 , 7 , 8 ]; prediction of these cutting forces during micro end milling considering chip thickness [ 9 , 10 ]; and the modeling of the effects of runout, minimum chip thickness, and elastic recovery on the cutting forces [ 11 , 12 , 13 , 14 ]. However, these models were only able to explain the initial condition of the cutting tool, whereas the actual machining phenomena changes with the tool wear continued to progress.…”

Section: Introductionmentioning

confidence: 99%

An Experimental Investigation on Micro End Milling with High-Speed Up Cut Milling for Hardened Die Steel

Kino¹,

Imada²,

Ogawa

et al. 2020

Materials

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The importance of micromachining using small diameter end mills and the dies used for them has been increasing in the machining of small parts. However, the reality is that there are various requirements to improve the machining surface, machining accuracy, machining efficiency, and tool life. Therefore, this paper discusses the possibility of satisfying these requirements by high-speed up cut milling in side cutting. The goal of this study was to solve the aforementioned problems, by conducting a detailed analysis of the machining phenomena in order to understand their mechanisms. In particular, the effects of high-speed cutting using a high-speed air-turbine spindle with highly stiff rolling bearings were analyzed. Moreover, cutting experiments were conducted by measuring the cutting force and flank wear of the tool, to reveal the differences in the cutting phenomena relative to the cutting direction in high-speed micro end milling. Description of the machined surface and the measurement of its profile were also included in the discussions. On the basis of the results, high-speed up cut milling is a better choice than down cut milling; furthermore, a high-feed rate further increases machining efficiency and improves tool life.

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“…He also investigated the influence of the worn tool affected by built-up edge (BUE) on micro-end milling process performance via FEM, which demonstrates that the predicted micro-milling cutting forces resulted affected by BUE with different teeth engagements [19]. Zhang et al [20] proposed an analytical model by considering the minimum chip thickness effect, tool run-out (axial offset and tilt offset) and trochoidal trajectory to determine the cutting forces. These were seen as the most related influence factors in the force model and validated through experiments.…”

Section: Introductionmentioning

confidence: 99%

Investigation on Innovative Dynamic Cutting Force Modelling in Micro-milling and Its Experimental Validation

2018

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In this paper, an innovative cutting force modelling concept is presented by modelling cutting forces against micro-cutting processes such as micro-milling, ultraprecision turning and abrasive micromachining, and also taking account of microcutting dynamics. The modelling represents the underlying micro-cutting mechanics and physics in micro-milling in an innovative multi-scale manner, i.e. the specific cutting force at the unit length, unit area and unit volume by considering the size effect, cutting fracture energy, the material modulus, and the cutting heat and temperature partition. A novel instantaneous chip thickness algorithm is introduced to analyse the real chip thickness by taking account of the effects of the micro-tool geometry change brought up by the tool run-out and further contribute to the force model through a numerical iterative algorithm. The measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. This is further utilized to calibrate the model coefficients using least square method. The cutting force modelling is evaluated and validated through well-designed micro-milling trials, which can be used for optimizing the cutting process and tool cutting performance in particular.

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Prediction of cutting forces and instantaneous tool deflection in micro end milling by considering tool run-out

Cited by 65 publications

References 24 publications

Precision micro-milling process: state of the art

Precision micro-milling process: state of the art

An Experimental Investigation on Micro End Milling with High-Speed Up Cut Milling for Hardened Die Steel

Investigation on Innovative Dynamic Cutting Force Modelling in Micro-milling and Its Experimental Validation

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