Abstract
In this paper, an innovative cutting force modelling concept is presented by modelling cutting forces against micro-cutting processes such as micro-milling, ultraprecision turning and abrasive micromachining, and also taking account of micro-cutting dynamics. The modelling represents the underlying micro-cutting mechanics and physics in micro-milling in an innovative multi-scale manner, i.e. the specific cutting force at the unit length, unit area and unit volume by considering the size effect, cutting fracture energy, the material modulus, and the cutting heat and temperature partition. A novel instantaneous chip thickness algorithm is introduced to analyse the real chip thickness by taking account of the effects of the micro-tool geometry change brought up by the tool run-out and further contribute to the force model through a numerical iterative algorithm. The measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. This is further utilized to calibrate the model coefficients using least square method. The cutting force modelling is evaluated and validated through well-designed micro-milling trials, which can be used for optimizing the cutting process and tool cutting performance in particular.
Highlights
Cutting force modelling and analysis, as an important process indicator in micro-milling, can collectively reflect the various cutting process phenomena and dynamics such as size effect, chip formation, energy consumption and cutting heat partition, and the machining instability and chatter
This paper presents an innovative dynamic cutting force model by considering instantaneous chip thickness in micromilling and further investigates the scientific understanding of the relevant micro-cutting mechanics and the process dynamics
An innovative investigation on the micromilling mechanics is presented focusing on the innovative dynamic cutting force modelling and its intrinsic relationships with micro-milling chip formation, minimum chip thickness (MCT), cutting temperature partition and surface generation, etc. further supported by experimental evaluation and validation
Summary
Cutting force modelling and analysis, as an important process indicator in micro-milling, can collectively reflect the various cutting process phenomena and dynamics such as size effect, chip formation, energy consumption and cutting heat partition, and the machining instability and chatter. A comprehensive cutting force modelling, representing the micro-milling forces at the unit length, unit area and further at the unit volume, is proposed in order to establish scientific understanding of the underlying microcutting mechanics and physics in a multi-scale manner This innovative modelling is expected to be industrial feasible and realistic compared to the existing models, and to take account of the size effect, chip formation, tool wear mechanism and the cutting temperature partition, etc. The approach is evaluated and validated through well-designed experimental trials, which will likely help the micro-milling process optimization with the application to industrial micro-manufacturing
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