Cutting forces modeling for micro flat end milling by considering tool run-out and bottom edge cutting effect. (January 2019)

• Record Type: Journal Article
• Authors: Zhang, Xuewei; Yu, Tianbiao; Wang, Wanshan
• Is Part Of: Proceedings of the Institution of Mechanical Engineers. Volume 233:Number 2(2019)
• Page Start: 470
• Page End: 485
• Publication Date: 2019-01
• Subjects: Micro flat end milling -- tool run-out -- bottom edge cutting effect -- cutting forces -- uncut chip thickness; Mechanical engineering -- Periodicals; Engineering -- Management -- Periodicals; Manufacturing processes -- Periodicals; 629.8
• DOI: 10.1177/0954405417726811
• Languages: English
• ISSNs: 0954-4054

Abstract

In this article, a cutting forces model for micro flat end milling is developed by regarding tool run-out or eccentric and tilt deviation of tool path as well as the effect of bottom edge cutting. Since the chip thickness is comparable to the edge radius, the size effect, which means the chip is only removed when it is higher than a certain value, is also taken into account. Therefore, cutting forces of the proposed model are calculated by flank shearing, flank ploughing and bottom edge cutting mechanisms in the shearing-domain and ploughing-domain regimes. The coefficients of cutting forces and tool run-out parameters can be calibrated by the experimental cutting forces. The predicted cutting forces with different feed rates and axial depths of cut based on the proposed model have been investigated and compared with experimental results for Al6061. The predicted and measured cutting forces are in good agreement.