Theoretical study on the effects of the axial and radial runout and tool corner radius on surface roughness in slot micromilling process

Abstract

This paper presented a theoretical study on the effects of the axial and radial runout and tool corner radius on surface roughness in the slot micromilling process. Firstly, the actual feed rate was calculated based on the optimized model for the uncut chip thickness. Then, the milled morphologies in five typical cases are analyzed, and the details of the flowchart for the modeling process are drawn, and the corresponding surface morphology and surface roughness are presented. Next, the effects of radial runout offset and angle, axial offset, and tool corner radius on surface roughness were studied. Furthermore, three typical surface morphologies, i.e., a single cutting phenomenon, unbalanced cutting phenomena due to the radial runout and axial runout, were obtained from the slot micromilling experiment, which could verify the validity of the model indirectly. In the end, the approaches for improving the predicting accuracy were discussed. The findings could provide a better understanding of the surface formation process during slot micromilling process.