Tool runout effects on wear and mechanics behavior in microend milling

2009 ◽  
Vol 27 (3) ◽  
pp. 1566 ◽  
Author(s):  
Q. S. Bai ◽  
K. Yang ◽  
Y. C. Liang ◽  
C. L. Yang ◽  
B. Wang
Keyword(s):  
Tool Runout ◽  
Microend Milling

scholarly journals An In-Process Intervention to Mitigate the Effect of Built-Up Edges in Micromilling

2017 ◽  
Vol 5 (4) ◽  
Author(s):  
Robert G. Altman ◽  
James F. Nowak ◽  
Johnson Samuel
Keyword(s):  
Machining Process ◽  
Burr Formation ◽  
Tool Runout ◽  
Part Geometry ◽  
Intervention Technique ◽  
Mechanical Removal ◽  
Working Volume ◽  
G Code ◽  
Critical Process Parameters ◽  
Critical Process

This paper is focused on developing an in-process intervention technique that mitigates the effect of built-up edges (BUEs) during micromilling of aluminum. The technique relies on the intermittent removal of the BUEs formed during the machining process. This is achieved using a three-stage intervention that consists first of the mechanical removal of mesoscale BUEs, followed by an abrasive slurry treatment to remove the microscale BUEs. Finally, the tool is cleaned using a nonwoven fibrous mat to remove the slurry debris. An on-machine implementation of this intervention technique is demonstrated, followed by a study of its influence on key micromachining outcomes such as tool wear, cutting forces, part geometry, and burr formation. In general, all relevant machining measures are found to improve significantly with the intervention. The key attributes of this intervention that makes it viable for micromachining processes include the following: (i) an experimental setup that can be implemented within the working volume of the microscale machine tool; (ii) no removal of the tool from the spindle, which ensures that the intervention does not change critical process parameters such as tool runout and offset values; and (iii) implementation in the form of canned G-code subroutines dispersed within the regular micromachining operation.

Investigation of the Dynamics of Microend Milling—Part I: Model Development

2006 ◽  
Vol 128 (4) ◽  
pp. 893-900 ◽  
Author(s):  
Martin B. G. Jun ◽  
Xinyu Liu ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Model Development ◽  
Chip Thickness ◽  
Fault System ◽  
Formation Mechanisms ◽  
Force Model ◽  
Line Field ◽  
Fault Parameters ◽  
Microend Milling

In microend milling, due to the comparable size of the edge radius to chip thickness, chip formation mechanisms are different. Also, the design of microend mills with features of a large shank, taper, and reduced diameter at the cutting edges introduces additional dynamics and faults or errors at the cutting edges. A dynamic microend milling cutting force and vibration model has been developed to investigate the microend milling dynamics caused by the unique mechanisms of chip formation as well as the unique microend mill design and its associated fault system. The chip thickness model has been developed considering the elastic-plastic nature in the ploughing process. A slip-line field modeling approach is taken for a cutting force model development that accounts for variations in the effective rake angle and dead metal cap. The process fault parameters associated with microend mills have been defined and their effects on chip load have been derived. Finally, a dynamic model has been developed considering the effects of both the unique microend mill design and fault system and factors that become significant at high spindle speeds including rotary inertia and gyroscopic moments.

Substructure Coupling of Microend Mills to Aid in the Suppression of Chatter

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
Brock A. Mascardelli ◽  
Simon S. Park ◽  
Theodor Freiheit
Keyword(s):  
Finite Element ◽  
Complex Geometry ◽  
Rotational Dynamics ◽  
Response Functions ◽  
Finite Element Analyses ◽  
Coupling Technique ◽  
Good Surface ◽  
Receptance Coupling ◽  
Milling Tool ◽  
Microend Milling

Microend milling offers the ability to machine microparts of complex geometry relatively quickly when compared with photolithographic techniques. The key to good surface quality is the minimization of tool chatter. This requires an understanding of the milling tool and the milling structure system dynamics. However, impact hammer testing cannot be applied directly to the prediction of tool tip dynamics because microend mills are fragile, with tip diameters as small as 10μm. This paper investigates the application of the receptance coupling technique to mathematically couple the spindle/micromachine and arbitrary microtools with different geometries. The frequency response functions (FRFs) of the spindle/micromachine tool are measured experimentally through impact hammer testing, utilizing laser displacement and capacitance sensors. The dynamics of an arbitrary tool substructure are determined through modal finite element analyses. Joint rotational dynamics are indirectly determined through experimentally measuring the FRFs of gauge tools. From the FRFs, chatter conditions are predicted and verified through micromilling experiments.

Surface Prediction Model of Micro-Endmilling Based on the Geometries and Tool Runout

2012 ◽  
Vol 14 (1) ◽  
pp. 231-238
Author(s):  
Gun-Hee Kim ◽  
Gil-Sang Yoon ◽  
Myeong-Woo Cho
Keyword(s):  
Prediction Model ◽  
Tool Runout ◽  
Surface Prediction

Investigation of the Dynamics of Microend Milling—Part II: Model Validation and Interpretation

2006 ◽  
Vol 128 (4) ◽  
pp. 901-912 ◽  
Author(s):  
Martin B. G. Jun ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Dynamic Model ◽  
End Milling ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Thickness Effect ◽  
Depth Of Cut ◽  
Minimum Chip Thickness ◽  
Microend Milling ◽  
The Stability ◽  
Cutting Mechanisms

In Part II of this paper, experimental and analytical methods have been developed to estimate the values of the process faults defined in Part I of this paper. The additional faults introduced by the microend mill design are shown to have a significant influence on the total net runout of the microend mill. The dynamic model has been validated through microend milling experiments. Using the dynamic model, the effects of minimum chip thickness and elastic recovery on microend milling stability have been studied over a range of feed rates for which the cutting mechanisms vary from ploughing-dominated to shearing-dominated. The minimum chip thickness effect is found to cause feed rate dependent instability at low feed rates, and the range of unstable feed rates depends on the axial depth of cut. The effects of process faults on microend mill vibrations have also been studied and the influence of the unbalance from the faults is found to be significant as spindle speed is increased. The stability characteristics due to the regenerative effect have been studied. The results show that the stability lobes from the second mode of the microend mill, which are generally neglected in macroscale end milling, affect the microend mill stability significantly.

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

2021 ◽  
Author(s):  
Tongshun Liu ◽  
Yayun Liu ◽  
Kedong Zhang
Keyword(s):  
Tool Wear ◽  
Size Effect ◽  
Cutting Force ◽  
Cutting Edge ◽  
Micro Milling ◽  
Force Model ◽  
Force Coefficient ◽  
Tool Runout ◽  
Cutting Edge Radius ◽  
Edge Radius

Abstract 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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