Abstract
Micro milling is a flexible and economical method to fabricate micro components with three-dimensional geometry features over a wide range of engineering materials. But the surface roughness and micro topography always limit the performance of the machined micro components. This paper presents a surface generation simulation in micro end milling considering both axial and radial tool runout. Firstly, a surface generation model is established based on the geometry of micro milling cutter. Secondly, the influence of the runout in axial and radial directions on the surface generation are investigated and the surface roughness prediction is realized. It is found that the axial runout has a significant influence on the surface topography generation. Furthermore, the influence of axial runout on the surface micro topography was studied quantitatively, and a critical axial runout is given for variable feed per tooth to generate specific surface topography. Finally, the proposed model is validated by means of experiments and a good correlation is obtained. The proposed surface generation model offers a basis for designing and optimizing surface parameters of functional machined surfaces.
Highlights
Micro milling is recognized as one of the most versatile machining processes to fabricate micro components and micro features [1], due to the advantages including wide material choices, true 3D micro geometry machining capability, high accuracy, low cost and environmentally friendliness [2–5]
4 Conclusions In this paper, a surface generation model of micro end milling has been developed by taking into account tool runout in the machining process
A numerical model based on the geometry of the cutter profile is established to investigate the tool intersection caused by the tool runout
Summary
Micro milling is recognized as one of the most versatile machining processes to fabricate micro components and micro features [1], due to the advantages including wide material choices, true 3D micro geometry machining capability, high accuracy, low cost and environmentally friendliness [2–5]. Bissacco et al [17] studied the size effects on surface generation by ball nose and flat end micro milling of hardened tool steel, and the effects of the increased ratio between cutting edge radius and chip thickness have been observed. Li et al [19] proposed a trajectory-based surface roughness model for micro-end-milling and proven capable of capturing the minimum chip thickness, micro tool geometry and process parameters. Based on this model, a surface roughness model with tool wear effect is developed by taking the material removal volume and cutting velocity into account and is experimentally validated. Previous research studied the influence of geometry of the cutter, machining parameters, tool wear and minimum cutting chip thickness on the surface generation in micro milling. A surface generation model is proposed considering the tool runout both in axial and radial directions, after that the influence of the runout on the surface generation is studied quantitatively
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