Model of the instantaneous undeformed chip thickness in micro-milling based on tooth trajectory. (January 2018)

• Record Type: Journal Article
• Authors: Lu, Xiaohong; Jia, Zhenyuan; Wang, Furui; Li, Guangjun; Si, Likun; Gao, Lusi
• Is Part Of: Proceedings of the Institution of Mechanical Engineers. Volume 232:Number 2(2018)
• Page Start: 226
• Page End: 239
• Publication Date: 2018-01
• Subjects: Radial runout -- micro-milling -- instantaneous undeformed chip thickness -- tooth trajectory; Mechanical engineering -- Periodicals; Engineering -- Management -- Periodicals; Manufacturing processes -- Periodicals; 629.8
• DOI: 10.1177/0954405416639890
• Languages: English
• ISSNs: 0954-4054

Abstract

Instantaneous undeformed chip thickness is one of the key parameters in modeling of micro-milling process. Most of the existing instantaneous undeformed chip thickness models in meso-scale cutting process are based on the trochoidal trajectory of the cutting edge, which neglect the influences of cutter installation errors, cutter-holder manufacturing errors, radial runout of the spindle and so forth on the instantaneous undeformed chip thickness. This article investigates the tooth trajectory in micro-milling process. A prediction model of radial runout of cutting edge is built, with consideration of the effects of the extended length of micro-milling cutter and the spindle speed. Considering the effects of cutting-edge trochoidal trajectory, radial runout of cutting edge and the minimum cutting thickness, a novel instantaneous undeformed chip thickness model is proposed, and the phenomenon of single-tooth cutting in micro-milling process is analyzed. Comparisons of cutting forces under different chip thickness models and experimental data indicate that this new model can be used to predict cutting forces.