Abstract
In micro-milling, cutting forces generate non-negligible tool deflection, which has a significant influence on the machining process and on workpiece accuracy. This paper investigates the tool deflection during micro-milling and its effect on cutting force and surface generation. The distribution of cutting forces acting on the tool is calculated with a mathematical model that considers tool elasticity and runout, and the tool deflection caused by the cutting forces is then obtained. Furthermore, an improved cutting force model and side wall surface generation model are established, including the tool deflection effect. Both cutting force and surface simulation models were verified by the micro-end-milling experiment, and the results show a very good agreement between the simulation and experiments.
Highlights
Increasing demands on precision micro-parts, components, and systems have led to the development of micro- and nano-manufacturing technologies
Tool deflection caused by cutting forces during machining could affect surface roughness, as well as form and dimensional precision, which is believed to be more prominent in micro-milling compared with its conventional scale counterpart
It is imperative that the influence of tool deflections in micro-milling operations be investigated so as to control the cutting process and to predict machining accuracy
Summary
Increasing demands on precision micro-parts, components, and systems have led to the development of micro- and nano-manufacturing technologies. Tool deflection caused by cutting forces during machining could affect surface roughness, as well as form and dimensional precision, which is believed to be more prominent in micro-milling compared with its conventional scale counterpart. It is imperative that the influence of tool deflections in micro-milling operations be investigated so as to control the cutting process and to predict machining accuracy.
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