Abstract
The interest in micro manufacturing processes is increasing because of the need for components characterized by small dimensions and micro features. As a result, researchers are studying the limitations and advantages of these processes. This paper deals with tool run-out measurement in micro milling. Among the effects of the scale reduction from macro to micro, tool run-out plays an important role, affecting cutting force, tool life, and the surface integrity of the produced part. The aim of this research is to develop an easy and reliable method to measure tool run-out in micro milling. This measuring strategy, from an Industry 4.0 perspective, can be integrated into an adaptive model for controlling cutting force, with the aim of improving the production quality and the process stability, while at the same time reducing tool wear and machining costs. The proposed procedure deduces tool run-out from the actual tool diameter, the channel width, and the cutting edge’s phase, which is estimated by analyzing the cutting force signal. In order to automate the cutting edge phase measurement, the suitability of two functions approximating the force signal was evaluated. The developed procedure was tested on data from experimental tests. A Ti6Al4V sample was machined using two coated micro end mill flutes made by SECO setting different run-out values. The results showed that the developed procedure can be used for tool run-out estimation.
Highlights
Micro manufacturing processes are becoming fundamental in several industrial fields
The results showed that the developed procedure can be used for tool run-out estimation
Dornfeld et al [2] referred to their modified version of the Taniguchi graph [3], which shows the development of the manufacturing capability in terms of achievable machining accuracy, when they defined micro machining as a process in which the accuracy is lower than 1 microns
Summary
Micro manufacturing processes are becoming fundamental in several industrial fields. The need for having products characterized by very small dimensions and features is continuously increasing in biomedical, mechanical, automotive and aerospace applications. An analytical model for predicting the three-dimensional cutting forces of micro-end milling processes, based on the trochoidal trajectory of the cutting edge and tool run-out, was developed by Micromachines 2017, 8, 221. This model is based on six optimized coefficients, which minimizes the errors between the model and the experimental force values through the least square methods They studied the influence of feed per tooth and tool run-out on the uncut chip thickness of each cutting edge. The limitation of this model is that the six coefficients are not constant; they are optimized at every spindle rotation.
Sign-in/Register to view highlights & summary Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
