Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method

被引：5

作者：

Bhople N. ^{[1
]}

Mastud S. ^{[2
]}

Satpal S. ^{[3
]}

机构：

[1] Department of Production Engineering, VJTI, Mumbai

[2] Department of Mechanical Engineering, VJTI, Mumbai

[3] Department of Mechanical Engineering, NTC, Pune

来源：

International Journal for Simulation and Multidisciplinary Design Optimization | 2021年 / 12卷

关键词：

Cutting force; Finite element method; Micro-end milling; Surface roughness; Ti-6Al-4V; Tungsten carbide; Von-Misses stress;

D O I：

10.1051/smdo/2021027

中图分类号：

学科分类号：

摘要：

Micromilling is one of the preferable micro-manufacturing process, as it exhibits the flexibility to produce complex 3D micro-parts. The cutting forces generated in micro end milling can be attributed for tool vibration and process instability. If cutting forces are not controlled below critical limits, it may lead to catastrophic failure of tool. Cutting force has a significant role to decide the surface roughness. Therefore accurate prediction of cutting forces and selection of suitable cutting parameters mainly feed, is important while micro end milling. In present study, finite element method (FEM) based model has been developed by using ABAQUAS/Explicit 6.12 software. Von-Misses stresses and cutting forces are predicted while micro end milling of Ti-6Al-4V. Further, cutting forces were measured during experimentation using dynamometer mounted on micro-milling test bed. Cutting forces predicted by FEM model are in good agreement with the experimental force values. Obtained FEM results have been used to study the size effect in micro end milling process. Moreover, the effect of uncut chip thickness to cutting edge radius ratio (h/rc) on surface roughness (Ra) has been studied. It is found the feed 2.5 μm/tooth is suitable value to produce optimum surface roughness and cutting forces. © N. Bhople et al., Published by EDP Sciences, 2021.

引用

共 25 条

[1]

Camara M.A., Rubio Campos J.C., Abrao A.M., Davim J.P., State of the art on Micromilling of material: a review, J. Mater. Sci. Technol., 28, pp. 673-685, (2012)

[2]

Mittal R., Kulkarni S., Singh R., Effect of lubrication on machining response and dynamic instability in high-speed micromilling of Ti-6Al-4V, J. Manufactur. Process., 28, pp. 413-421, (2017)

[3]

Rahman M., Kumar A.S., Prakash J.R.S., Micro milling of pure copper, J. Mater. Process. Technol., 116, pp. 39-43, (2001)

[4]

Ducobu F., Filippi E., Rivie E re-Lorphever, Chip formation in micro-milling, Proceedings of the 8th National Congress on Theoretical and Applied Mechanics, pp. 333-339, (2010)

[5]

Chae J., Park S., Freiheit T., Investigation of micro-cutting operations, Int. J. Mach. Tools Manufact., 46, pp. 313-332, (2006)

[6]

Aramcharoen A., Mativenga P.T., Size effect and tool geometry in micromilling of tool steel, Precis. Eng., 33, pp. 402-407, (2009)

[7]

Bissacco G., Hansen H., Chiffre L., Micromilling of hardened tool steel for mould making applications, J. Mater. Process. Technol., 167, pp. 201-207, (2005)

[8]

Barnabas B., Norbert G., Marton T., Davim J., A review on micro-milling: recent advances and future trends, Int. J. Adv. Manufactur. Technol., 112, pp. 655-684, (2021)

[9]

Liu X., Devor R.E., Kapoor S.G., Ehmann K.F., The mechanics of machining at the micro scale: assessment of the current state of the science, Trans. ASME J. Manuf. Sci. Eng., 126, pp. 666-678, (2004)

[10]

Dornfeld D., Min S., Takeuchi Y., Recent advances in mechanical micromachining, Ann. CIRP Manuf. Technol., 55, pp. 745-769, (2006)

← 1 2 3 →