ANALYTICAL CHIP FORMATION MODEL OF MICRO-END-MILLING

A new analytical chip formation model is proposed for micro-end-milling operations. The model calculates an instantaneous uncut chip thickness by considering the combination of exact trochoidal trajectory of the tool tip and tool run-out, while the simplified circular trajectory and the neglected run-out create negligible change in conventional-scale chip formation models. Newton-Raphson iterative method is employed during the calculation to obtain quadratic convergence. The proposed approach allows the calculation of instantaneous uncut chip thickness to be done accurately and rapidly, and the prediction accuracy of this model is also verified by comparing the simulation results to experimental cutting forces.

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6

Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling （3D FEM） approach for the micro end-milling orAl6061-T6. Finite element （FE） simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects ofmiU helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.

Investigation into machining performance of microstructurally engineered in-situ particle reinforced magnesium matrix composite

Magnesium and magnesium in-situ composites have significant potential in the application of design and manufacturing for automotive and aerospace industries because of their high specific strength and reduced fuel consumption.But there are many challenges for machining of Mg based alloys and composites because of the high tendency of fire and oxidation.These challenges can be minimized through microstructural engineering.In this present study,the machining performances of AZ91 Mg alloy and in-situ hybrid TiC+TiB_(2)reinforced AZ91 metal matrix composite was investigated.The effectβ-Mg_(17)Al_(12)phases and grain refinement with and without in-situ particles on machinability were studied through microstructural engineering via aging and friction stir processing.The end milling operation was carried out at different cutting speeds ranging from 25 mm/min to 90 mm/min under dry environment by using an AlTiN-coated tungsten carbide tool.The optimum cutting speed for machining was found to be 75 mm/min based on the surface roughness values of all conditioned materials.The base material with dendritic microstructure was found to have poor machinability in terms of inadequate surface finish and edge-burrs formation.The combined effect of in-situ TiC+TiB_(2)particles addition and grain refinement enhanced the machining performance of the material with superior surface finish,negligible edge-burr formation and better tool wear resistance.The influence of in-situ TiC+TiB_(2)particles,β-Mg_(17)Al_(12)phases and grain refinement on machining characteristics are explained based on the tool wear mechanisms,chip behavior and machining induced affected zone.

Study on High-Performance Computing for Simulation of End Milling Force

Milling Process Simulation is one of the important re search areas in manufacturing science. For the purpose of improving the prec ision of simulation and extending its usability, numerical algorithm is more and more used in the milling modeling areas. But simulative efficiency is decreasin g with increase of its complexity. As a result, application of the method is lim ited. Aimed at above question, high-efficient algorithm for milling process sim ulation is studied. It is important for milling process simulation’s applicatio n. Parallel computing is widely used to solve the large-scale computation question s. Its advantages include system flexibility, robust, high-efficient computing capability and high ratio of performance to price. With the development of compu ter network, utilizing the computing resource in the Internet, a virtual computi ng environment with powerful computing capability can be consisted by microc omputers, and the difficulty of building hardware environment which is used to s upport parallel computing is reduced. How to use network technology and parallel algorithm to improve simulative effic iency for milling forces simulation is investigated in the paper. In order to pr edict milling forces, a simplified local milling forces model is used in the pap er. End milling cutter is assumed to be divided by r number of differential elem ents along the axial direction of the cutter. For a given time, the total cuttin g forces can be obtained by summarizing the resultant cutting force produced by each differential cutter disc. Divide the whole simulative time into some segmen ts, send these program’s segments to microcomputers in the Internet and obtain the result of the program’s segments, all of the result of program’s segments a re composed the final result. For implementing the algorithm, a distributed Parallel computing framework is de signed in the paper. In the framework, web server plays a role of controller. Us ing Java RMI(remote method interface), the computing processes in computing serv er are called by web server. There are lots of control processes in web server a nd control the computing servers. The codes of simulative algorithm can be dynam ic sent to the computing servers, and milling forces at the different time are c omputed through utilizing the local computer’s resource. The results that are ca lculated by every computing servers are sent to the web server, and composed the final result. The framework can be used by different simulative algorithm. Comp ared with the algorithm running single machine, the efficiency of provided algor ithm is higher than that of single machine.

An Experimental Study on Slotting of Inconel 718 Thin Sheet

Many difficult-to-cut materials such as Ni-base super alloy, titanium alloy, and austenite stainless steel which are used extensively in aerospace generally have high strength-to-weight ratios, high corrosion resistance, high strength retention ability at elevated temperatures, and low thermal conductivity. These characteristics can result in uneven tool wear and chatter vibration. Therefore, determining the appropriate end-milling conditions is more difficult for difficult-to-cut materials than for other materials. There has been much research on the high-speed milling of difficult-to-cut materials, and effective end-milling conditions, end-mill tool shapes, and processing methods have been reported. In addition, irregular pitch and lead end-mills with different helix angles have been developed by tool maker＇s to reduce chatter vibration, making it easier to perform high-speed milling. However, there have been few reports of slotting information useful for determining appropriate end-milling conditions and processing methods for Ni-base super alloy. The aim of this study is to derive end-milling condition with high efficiency grooving process for Ni-base super alloy （Inconel 718） sheet. Effects of cutting parameters were examined from the view point of cutting resistance, ＂tool tip maximum temperature and tool flank wear width. As a result from experiments, if the grooving process condition of axial depth of cut is smaller than other conditions on the same material removable rate value, it has been found that it is possible to reduce the tool tip maximum temperature and prolong the tool life.

Online tool-wear measurement of small-diameter end mills based on machine vision

The objective of this study was to develop an online tool-wear-measurement scheme for small diameter end-mills based on machine vision to increase tool life and the production efficiency. The geometrical features of wear zone of each end mill were analyzed, and three tool wear criterions of small-diameter end mills were defined. With the uEye camera, macro lens and 3-axis micro milling machine, it was proved the feasibility of measuring flank wear with the milling tests on a 45# steel workpiece. The design of experiment （DOE） showed that Vc was the most remarkable effect factor for the flank wear of small-diameter end mill. The wear curve of the experiments of milling was very similar to the Taylor curve.