Abstract
In this paper, the reliability of a new online cutting edge radius estimator for micro end milling is evaluated. This estimator predicts the cutting edge radius by detecting the drop in the chip production rate as the cutting edge of a micro end mill slips over the workpiece when the minimum chip thickness (MCT) becomes larger than the uncut chip thickness (UCT), thus transitioning from the shearing to the ploughing dominant regime. This study proposes a method of calibrating the cutting edge radius estimator by determining two parameters from training data: a ‘size filtering threshold’ that specifies the smallest-size chip that should be counted, and a ‘drop detection threshold’ that distinguishes the drop in the number of chips at the actual critical feedrate from the number drops at the other feedrates. This study then evaluates the accuracy of the calibrated estimator from testing data for determining the ‘critical feedrate’—the feedrate at which the MCT and UCT will be equal. It is found that the estimator is successful in determining the critical feedrate to within 1 mm/s in 84% of trials.
Highlights
As the need for micro-components has grown in various engineering fields, the demand for technology development for micro-manufacturing has increased [1]
In order to overcome these drawbacks, a cutting edge radius estimator based on chip production rate has been developed
A chip production rate simulation has shown that the number of chips produced decreases when the minimum chip thickness (MCT) becomes larger than the uncut chip thickness (UCT) [33]
Summary
As the need for micro-components has grown in various engineering fields, the demand for technology development for micro-manufacturing has increased [1]. In micro milling, the cutting mechanism is divided into shearing/ploughing by the MCT effect which has a great influence on cutting force, chip production, surface quality, and tool wear [9,10,11]. In order to clarify the relationships between the MCT effect, the chip formation, the cutting force, the vibration, the surface quality, and the tool wear in micro-milling, many studies have been conducted. In order to overcome these drawbacks, a cutting edge radius estimator based on chip production rate has been developed This estimator can operate as an online system by measuring the chip production rate during the cutting process and yet it is based on the MCT effect which explains the physical relationship between the cutting edge radius and the measured data [32]. The conclusion and discussion are described in the last section
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