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    A Comprehensive Micro-Milling Force Model for a Low-Stiffness Machining System

    Source: Journal of Manufacturing Science and Engineering:;2021:;volume( 143 ):;issue: 011::page 0111004-1
    Author:
    Qu, Da
    ,
    Wang, Bo
    ,
    Gao, Yuan
    ,
    Cao, Huajun
    DOI: 10.1115/1.4051005
    Publisher: The American Society of Mechanical Engineers (ASME)
    Abstract: Micro-milling is widely used in various crucial fields with the ability of machining micro- and meso-scaled functional structures on various materials efficiently. However, the micro-milling force model is not comprehensively developed yet when tool feature sizes continually decrease to under 200 µm in a low-stiffness system. This paper proposes an analytical force model considering the influence of tool radius, size effect, tool runout, tool deflection, and the actual trochoidal trajectories and the interaction of historical tool teeth trajectories (IHTTT). Different micro-milling status are recognized by analyzing the cutting process of different tool teeth. Conditions of single-tooth cutting status are determined by a proposed numerical algorithm, and entry angle and exit angle are analyzed under various cutting conditions for the low-stiffness system. Three micro-milling status, including single-tooth cutting status, are distinguished based on the instantaneous undeformed chip thickness resulting in three types of material removal mechanisms in predicting micro-milling force components. Discontinuous change rates of undeformed chip thickness are found in the low-stiffness micro-milling system. The proposed micro-milling force model is then verified through experiments of micro slot milling Elgiloy alloy with a 150-μm-diametrical two-teeth micro-end mill. The experimental results show a root-mean-square error (RSME) of 0.092 N in the predicted resultant force, accounting for approximately 5.12% of the measured force, by which the proposed theoretical model is verified to be of good prediction accuracy.
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      A Comprehensive Micro-Milling Force Model for a Low-Stiffness Machining System

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    http://yetl.yabesh.ir/yetl1/handle/yetl/4278633
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    contributor authorQu, Da
    contributor authorWang, Bo
    contributor authorGao, Yuan
    contributor authorCao, Huajun
    date accessioned2022-02-06T05:43:45Z
    date available2022-02-06T05:43:45Z
    date copyright6/10/2021 12:00:00 AM
    date issued2021
    identifier issn1087-1357
    identifier othermanu_143_11_111004.pdf
    identifier urihttp://yetl.yabesh.ir/yetl1/handle/yetl/4278633
    description abstractMicro-milling is widely used in various crucial fields with the ability of machining micro- and meso-scaled functional structures on various materials efficiently. However, the micro-milling force model is not comprehensively developed yet when tool feature sizes continually decrease to under 200 µm in a low-stiffness system. This paper proposes an analytical force model considering the influence of tool radius, size effect, tool runout, tool deflection, and the actual trochoidal trajectories and the interaction of historical tool teeth trajectories (IHTTT). Different micro-milling status are recognized by analyzing the cutting process of different tool teeth. Conditions of single-tooth cutting status are determined by a proposed numerical algorithm, and entry angle and exit angle are analyzed under various cutting conditions for the low-stiffness system. Three micro-milling status, including single-tooth cutting status, are distinguished based on the instantaneous undeformed chip thickness resulting in three types of material removal mechanisms in predicting micro-milling force components. Discontinuous change rates of undeformed chip thickness are found in the low-stiffness micro-milling system. The proposed micro-milling force model is then verified through experiments of micro slot milling Elgiloy alloy with a 150-μm-diametrical two-teeth micro-end mill. The experimental results show a root-mean-square error (RSME) of 0.092 N in the predicted resultant force, accounting for approximately 5.12% of the measured force, by which the proposed theoretical model is verified to be of good prediction accuracy.
    publisherThe American Society of Mechanical Engineers (ASME)
    titleA Comprehensive Micro-Milling Force Model for a Low-Stiffness Machining System
    typeJournal Paper
    journal volume143
    journal issue11
    journal titleJournal of Manufacturing Science and Engineering
    identifier doi10.1115/1.4051005
    journal fristpage0111004-1
    journal lastpage0111004-19
    page19
    treeJournal of Manufacturing Science and Engineering:;2021:;volume( 143 ):;issue: 011
    contenttypeFulltext
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