A New Method for the Prediction of Micro-Milling Tool Breakage

2017 ◽  
Author(s):  
Xiaohong Lu ◽  
Haixing Zhang ◽  
Zhenyuan Jia ◽  
Yixuan Feng ◽  
Steven Y. Liang
Keyword(s):  
Cutting Parameters ◽  
Ultimate Stress ◽  
New Method ◽  
Micro Milling ◽  
Force Model ◽  
Bending Stress ◽  
Tool Breakage ◽  
Parameters Selection ◽  
Milling Tool ◽  
Milling Force Model

Micro-milling tool breakage has become a bottleneck for the development of micro-milling technology. A new method to predict micro-milling tool breakage based on theoretical model is presented in this paper. Based on the previously built micro-milling force model, the bending stress of the micro-milling cutter caused by the distributed load along the spiral cutting edge is calculated; Then, the ultimate stress of carbide micro-milling tool is obtained by experiments; Finally, the bending stress at the dangerous part of the micro-milling tool is compared with the ultimate stress. Tool breakage curves are drawn with feed per tooth and axial cutting depth as horizontal and vertical axes respectively. The area above the curve is the tool breakage zone, and the area below the curve is the safety zone. The research provides a new method for the prediction of micro-milling tool breakage, and therefore guides the cutting parameters selection in micro-milling.

scholarly journals Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

Micromachines ◽  
2021 ◽  
Vol 12 (12) ◽  
pp. 1495
Author(s):  
Tongshun Liu ◽  
Kedong Zhang ◽  
Gang Wang ◽  
Chengdong Wang
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Uncut Chip Thickness ◽  
Milling Force ◽  
Minimum Uncut Chip Thickness ◽  
Cutting Force Coefficient ◽  
Milling Force Model

The minimum uncut chip thickness (MUCT), dividing the cutting zone into the shear region and the ploughing region, has a strong nonlinear effect on the cutting force of micro-milling. Determining the MUCT value is fundamental in order to predict the micro-milling force. In this study, based on the assumption that the normal shear force and the normal ploughing force are equivalent at the MUCT point, a novel analytical MUCT model considering the comprehensive effect of shear stress, friction angle, ploughing coefficient and cutting-edge radius is constructed to determine the MUCT. Nonlinear piecewise cutting force coefficient functions with the novel MUCT as the break point are constructed to represent the distribution of the shear/ploughing force under the effect of the minimum uncut chip thickness. By integrating the cutting force coefficient function, the nonlinear micro-milling force is predicted. Theoretical analysis shows that the nonlinear cutting force coefficient function embedded with the novel MUCT is absolutely integrable, making the micro-milling force model more stable and accurate than the conventional models. Moreover, by considering different factors in the MUCT model, the proposed micro-milling force model is more flexible than the traditional models. Micro-milling experiments under different cutting conditions have verified the efficiency and improvement of the proposed micro-milling force model.

Analysis to Milling Force Base on AdvantEdge Finite Element Analysis

2014 ◽  
Vol 981 ◽  
pp. 895-898
Author(s):  
Fu Cai Zhang ◽  
Qing Wang ◽  
Ru Yang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Simulation Analysis ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cnc Milling ◽  
Milling Force ◽  
Element Analysis ◽  
Milling Force Model

Aiming at NC milling processing simulation problem, a ball-end cutter milling force model is established, the numerical simulation analysis of aluminum alloy AL2024 milling process is conducted by using the finite element analysis software AdvantEdge finite element analysis. Focus on the Milling force simulation, the size of the milling force is obtained by simulating calculation. Using the same cutting parameters for milling experiment, the results show that simulation analysis of the cutting force values ​​are in good agreement with the experimental results，the milling force model prior established is correct. The research laid a foundation for the perfect CNC milling simulation system.

Coupled thermal and mechanical analyses of micro-milling Inconel 718

2018 ◽  
Vol 233 (4) ◽  
pp. 1112-1126 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Yixuan Feng ◽  
Steven Y Liang
Keyword(s):  
Inconel 718 ◽  
Cutting Temperature ◽  
Milling Process ◽  
Micro Milling ◽  
Force Model ◽  
Temperature Model ◽  
Milling Force ◽  
Mechanical Coupling ◽  
Milling Forces ◽  
Milling Force Model

Micro-milling forces, cutting temperature, and thermal–mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal–mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal–mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier’s law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal–mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.

scholarly journals Research on Parameter Optimization of Micro-Milling Al7075 Based on Edge-Size-Effect

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 197 ◽  
Author(s):  
Yinghua Chen ◽  
Tao Wang ◽  
Guoqing Zhang
Keyword(s):  
Size Effect ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Milling Force ◽  
Milling Tool ◽  
Cutting Parameters Optimization ◽  
Strong Size Effect ◽  
Edge Size

In the process of micro-milling, the appearance of the edge-size-effect of micro-milling tools cannot be ignored when the cutting parameters are smaller than the cutting edge arc radius (r0) of the micro-milling tool or close to it, and it could easily lead to low cutting efficiency and poor surface quality of the micro-slot. Through micro-milling experiments on Al7075-T6 materials, the change of milling force in the plough zone and shear zone during micro-milling was studied, and the minimum cutting thickness (hmin) range was determined to be 0.2r0–0.4r0 based on r0 of the micro-milling tool. Subsequently, the effect of fz/r0 (fz denotes feed rate per tooth) on the top burr formation of the micro-slot, the surface roughness (Ra) of the micro-slot bottom, and the milling force was studied, and a size-effect band of micro milling was established to determine the strong size-effect zone, transition size-effect zone, and the weak size-effect zone. Finally, two different fz/r0 in the strong size-effect zone and the weak size-effect zone are compared, which proves that the main purpose of the cutting parameters optimization of micro-milling is to avoid cutting parameters locating in the strong edge-size-effect zone. The above conclusions provide a theoretical basis for the selection of micro-milling cutting parameters, and an important reference in improving the surface quality of micro-milling.

Simulation and Optimal Selection of Pitch Angles Distribution for Variable Pitch Angles Helix End Mills

2010 ◽  
Vol 443 ◽  
pp. 285-290
Author(s):  
Pan Ling Huang ◽  
Jian Feng Li ◽  
Jie Sun
Keyword(s):  
Cutting Parameters ◽  
Force Model ◽  
Optimal Selection ◽  
Milling Force ◽  
Frequency Spectra ◽  
Variable Pitch ◽  
End Mills ◽  
Milling Forces ◽  
Milling Force Model ◽  
Selection Of

In the paper, a static milling force model for variable pitch mills was built, and the milling forces were simulated. The resultant force and its frequency spectra of variable pitch mills were analyzed compared with that of uniform pitch mills. It is shown that the standard deviation (SD) of frequency spectra amplitudes for variable pitch mills is extremely lower than that of uniform pitch mills. Through simulation for SD of frequency spectra amplitudes affected by the different cutting parameters, a pitch angles distribution of variable pitch helix end mills with lower SD of frequency spectra amplitudes was selected.

Determination of Cutting Forces for Micro Milling

2008 ◽  
Author(s):  
Shih-Ming Wang ◽  
Zou-Sung Chiang ◽  
Da-Fun Chen
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Micro Milling ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model ◽  
Optimal Cutting Parameters

To enhance the implementation of micro milling, it is necessary to clearly understand the dynamic characteristics of micro milling so that proper machining parameters can be used to meet the requirements of application. By taking the effect of minimum chip thickness and rake angle into account, a new cutting force model of micro-milling which is function the instantaneous cutting area and machining coefficients was developed. According to the instantaneous rotation trajectory of cutting edge, the cutting area projected to xy-plane was determined by rectangular integral method, and used to solve the instantaneous cutting area. After the machining coefficients were solved, the cutting force of micro-milling for different radial depths of cut and different axial depths of cut can be predicted. The results of micro-milling experimental have shown that the force model can predict the cutting force accurately by which the optimal cutting parameters can be selected for micro-milling application.

scholarly journals The Predictive Research of Dynamic Milling Force Based on Data Mining

2021 ◽  
Author(s):  
Lan Jin ◽  
Xinlei Zeng ◽  
Shiqi Lu ◽  
Liming Xie ◽  
Xuefeng Zhang
Keyword(s):  
Data Mining ◽  
Rbf Neural Network ◽  
Cutting Parameters ◽  
Production Quality ◽  
Work Piece ◽  
Force Model ◽  
Milling Force ◽  
Using Data ◽  
Milling Force Model ◽  
Predictive Research

Abstract In this paper, surface accuracy of the work-piece was improved by mining large amounts of machining data and obtaining potentially valuable information. By using data mining technology, a dynamic milling force prediction model has been established to keep with its working. The model was developed by a combination of Regression Analysis and RBF Neural Network. The internal relation of the data were analyzed in this study, such as milling force, cutting parameters, temperature, vibration and surface quality et.al, and the methods of Cluster Analysis and Correlation Analysis was used to extract and induct dynamic milling force variations on the effects with different situations. The results suggest that the proposed dynamic milling force model had a better prediction effect, which ensure production quality, reduce the occurrence of chatter and provide a more accurate basis for selecting process parameters.

A Comprehensive Micro-milling Force Model for A Low-stiffness Machining System

2021 ◽  
pp. 1-42
Author(s):  
Da Qu ◽  
Bo Wang ◽  
Yuan Gao ◽  
Huajun Cao
Keyword(s):  
Chip Thickness ◽  
Micro Milling ◽  
Force Model ◽  
Milling Force ◽  
Undeformed Chip Thickness ◽  
Single Tooth ◽  
Good Prediction Accuracy ◽  
Low Stiffness ◽  
Milling Force Model ◽  
Tooth Cutting

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 two hundred microns 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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