Semi-analytic modelling of cutting forces in micro ball-end milling of NAK80 steel with wear-varying cutting edge and associated nonlinear process characteristics

Zhou, Lin; Deng, Ben; Peng, Fangyu; Yan, Rong

doi:10.1016/j.ijmecsci.2019.105343

Cited by 22 publications

(10 citation statements)

References 45 publications

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“…In the captured images, the tool can be in any positions, and the algorithm can evaluate it correctly. This is based on the fact that the size of the tool (which perpendicular to the cutting edges of the tool) does [4], [33], [38], [46], [48], [51], [54], [83], [88], [89], [122], [133], [144], [164], [165], [166], [167], [168] AISI 1015: [169] AISI 1018: [125] AISI 1040: [77] AISI 1050: [37] AISI 4340: [119], [139], [170] AISI P20: [20], [145], [164] S960QL: [171] NAK80: [123], [172], [173], [174] AISI A2-annealed: [175] 42CrMo4: [167] X13NiMnCuAl4-2-1-1: [146] SK2: [176] Hardened steels AISI H13: [2], [30], [42], [72], [80], [164], [177], [178], [179],…”

Section: Micro-milling Process Monitoringmentioning

confidence: 99%

“…9 Micro-milled workpiece material groups radius, there is an increased axial force component, which causes less bending-directional deformation in the tool than the cutting force, and also could be suitable to reduce the vibration [42]. Figure 10d shows the schematic of a ball-end micro mill, which is also commonly found in the scientific literature [174,184,255,276]. This type is especially suitable to produce complex 3D geometries.…”

Section: Micro-milling Tools and Coatingsmentioning

confidence: 99%

See 1 more Smart Citation

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

124

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Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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Section: Micro-milling Process Monitoringmentioning

confidence: 99%

Section: Micro-milling Tools and Coatingsmentioning

confidence: 99%

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

124

View full text Add to dashboard Cite

show abstract

“…Based on the study done on the effect of tool wear on final surface roughness at micro-level, tool wear directly proportional to the numbers of machined micro-dimple or materials removed volume [10][11] [12]. Despite the effect on the surface quality of the machined workpiece, tool wear also causing a significant increase in measured cutting force during machining [13], as well as excessive force, lead to tool breakage, which possibly led to decreased productivity.…”

Section: Introductionmentioning

confidence: 99%

Influence of Cutting Parameters to Surface Area Roughness in Dimple Machining Using Milling Process

Hanafiah

Aziz

Yusoff

2021

IJAME

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Surface quality is among the predominant criterion in measuring machining process performance, including milling. It is extremely dependent on the process variable, such as cutting parameters and cutting tool conditions. The main intention of this research work is to study the effect of the milling machining parameters, including depth of cut, spindle speed, feed rate as well as machining pattern to the final surface area roughness of the fabricated dimple structure. The concave profile of the dimple is machined at the right angle to a flat Al6061 specimen using a ball end mill attached to a 3-axis CNC milling machine, and the surface area of the concave profile is measured using 3D measuring laser microscope. It is observed that surface area roughness reacts with the spindle speed and feed rate with different tool sizes. Based on the result gained, the work has successfully characterised the influence of studied milling parameters on the dimple surface area roughness, where within the range of the studied parameter, the surface area roughness varies only less than 2.2 μm. The research work will be continued further on the incline milling technique and micro size ball end mill.

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“…Compared to the flank wear, the effect of cutting-edge wear on the cutting force is much less studied. By assuming that both of the edge radius and the flank wear width increase with the deteriorating tool wear condition, Zhou et al [22]attempted to build a cutting force model considering the edge wear and flank wear.…”

mentioning

confidence: 99%

“…Besides, some other studies have explored the influence of the pairwise combination of the three factors on the cutting force of micro-milling. The combined effect of the tool wear and cutting-edge radius on the force was reported in study [22]. Jing et al [8]considered the edge radius and runout, and built an analytic micro milling force model.…”

mentioning

confidence: 99%

An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

Liu¹,

Liu²,

Zhang³

2021

Preprint

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Tool runout, cutting edge radius-size effect and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the machining performance related to the cutting force, it is necessary to establish a cutting force model including tool runout, cutting edge radius and tool wear. In this study, an instantaneous uncut thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius and a friction force coefficient model embedded with flank wear width, are constructed respectively. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micromilling force model including the tool runout, size effect and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the micro milling force.

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Semi-analytic modelling of cutting forces in micro ball-end milling of NAK80 steel with wear-varying cutting edge and associated nonlinear process characteristics

Cited by 22 publications

References 45 publications

A review on micro-milling: recent advances and future trends

A review on micro-milling: recent advances and future trends

Influence of Cutting Parameters to Surface Area Roughness in Dimple Machining Using Milling Process

An Improved Cutting Force Model in Micro-milling Considering the Comprehensive Effect of Tool Runout, Size Effect and Tool Wear

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