New mathematic method of calculating instantaneous un-deformed chip thickness with tool run-out in micro-end-milling

被引：8
作者：
Nie Q. [1 ,2 ]
Huang K. [1 ,2 ]
Bi Q. [1 ,2 ]
Zhu L. [1 ,2 ]
机构：
[1] Institute of Robotics, Shanghai Jiao Tong University, Shanghai
[2] State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai
来源：
Jixie Gongcheng Xuebao/Journal of Mechanical Engineering | 2016年 / 52卷 / 03期
关键词：
Cutting mechanics; Micro-milling; Run-out; Tool trochoidal trajectory; Un-deformed chip thickness;
D O I：
10.3901/JME.2016.03.169
中图分类号：
学科分类号：
摘要：
A new mathematic method of calculating instantaneous un-deformed chip thickness is established through analysis of true cutting tool tip trajectories. Two specific formulas are given in condition of two-flute and four-flute micro end milling. Then cutting process of each tooth with tool run out is analyzed by applying the new method in two-flute and four-flute micro slot milling. This new method considered comprehensive radial cutter run-out which include the spindle run-out and assemble errors and can be used to calculate the un-deformed chip thickness of cutting tools with any number of teeth. The accuracy and practicability are verified and some differences between micro milling and traditional milling process are pointed out by comparing the new method with other methods such as Bao's and Newton-Raphson method. Cutting force is predicted based on the new method in micro slot milling experiment. The simulation result shows a very good agreement with experiment data. © 2016 Journal of Mechanical Engineering.
引用
收藏
页码：169 / 178
页数：9
相关论文
共 14 条
[1]  
Chae J., Park S.S., Freiheit T., Investigation of micro-cutting operations, International Journal of Machine Tools and Manufacture, 46, pp. 313-332, (2006)
[2]  
Cardoso P., Davim J.P., A brief review on Micromachining of materials, Rev. Adv. Mater. Sci., 30, pp. 98-102, (2012)
[3]  
Li H., Lai X., Li C., Et al., Development of meso-scale milling machine tool and performance analysis, Chinese Journal of Mechanical Engineering, 42, 11, pp. 162-167, (2006)
[4]  
Camara M.A., Campos Rubio J.C., Abrao A.M., Et al., State of the art on micromilling of materials, a review, J. Mater. Sci. Technol., 28, 8, pp. 673-685, (2012)
[5]  
Lee K., Dornfeld D., Micro-burr formation and minimization through process control, Precision Engineering, 29, pp. 246-252, (2005)
[6]  
Bao W.Y., Tansel I.N., Modeling micro-end-milling operations, Part I: analytical cutting force model, Int. J. Mach. Tools Manuf., 40, pp. 2155-2174, (2000)
[7]  
Bao W.Y., Tansel I.N., Modeling micro-end-milling operations, Part II: Tool run-out, Int. J. Mach. Tools Manuf., 40, pp. 2175-2192, (2000)
[8]  
Li H.Z., Liu K., Li X.P., A new method for determining the undeformed chip thickness in milling, J. Mater. Process. Technol., 113, pp. 378-384, (2001)
[9]  
Martellotti M.E., An analysis of the milling process. Part 2: Down milling, Trans. ASME, 67, pp. 233-251, (1945)
[10]  
Kang Y.H., Zheng C.M., Mathematical modeling of chip thickness in micro-end-milling: A Fourier modeling, Applied Mathematical Modeling, 37, pp. 4208-4223, (2013)
12