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 ...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.展开更多
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-m...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.展开更多
基金supported by National Natural Science Foundation of China (No.50575134)
文摘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.
文摘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.
