A Mechanistic Model of Cutting Force in the Micro End Milling Process

Июль 29, 2022

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A Mechanistic Model of Cutting Force in the Micro End Milling Process

Содержание

2. Introduction: What is micro end milling? 1mm - .04µm dia Applications of micro end milling Micro
3. Previous analyses Analytic cutting force of the conventional end mill as a function of chip thickness
4. Operator’s tool life Tool life is measured by: Visual inspection of tool edge Tool breaks Fingernail
5. Models & Design Principles Model based on the tool edge radius When depth of cut is
6. Tool edge radius affects cutting mechanisms Elastic recovery in the flank face of the work piece
7. Contact length of the tool on the work piece Chip thickness variation as a function of
8. Principal cutting force and thrust cutting force Final derivation of feed and normal cutting forces
9. Experiment
10. Results Previous experiments & models Conventional cutting Normal Force > Feed Force Micro cutting according to
12. Percent error was relatively low Percent error from existing models and experiments not cited for comparison
13. Conclusions Derived a model that predicted micro end milling cutting forces Included the tool edge radius
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Introduction:
What is micro end milling? 1mm - .04µm dia
Applications of micro

end milling
Micro end milling vs. Conventional end milling
Feed/tooth to tool radius
Cutting conditions
Detection of tool wear
Various cutting force analyses

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Previous analyses
Analytic cutting force of the conventional end mill as

a function of chip thickness and cutting area, Tlusty et al
Analytic cutting force model of micro end mill based on Tlusty , Bao et al
Major shortcomings
Based mainly on differences between tool tip trajectories
Ignored the effect of tool edge radius

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Operator’s tool life
Tool life is measured by:
Visual inspection of tool edge
Tool

breaks
Fingernail test
Changes in cutting sounds
Chips become ribbony, stringy
Surface finish degrades
Computer interface says
- power consumption up
- cumulative cutting time reaches certain level
- cumulative number of pieces cut reaches certain value

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Models & Design Principles
Model based on the tool edge radius
When depth

of cut is close or smaller than the tool edge radius, the radius effects cannot be ignored

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Tool edge radius affects cutting mechanisms
Elastic recovery in the flank face

of the work piece
Sliding due to the contact between the tool and the work piece
Ploughing due to the tool edge
These cutting mechanisms change the cutter forces in the feed and normal directions

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