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TECHNICAL PAPERS

Microstructure-Level Force Prediction Model for Micro-milling of Multi-Phase Materials

[+] Author and Article Information
Michael P. Vogler, Richard E. DeVor, Shiv G. Kapoor

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801

J. Manuf. Sci. Eng 125(2), 202-209 (Apr 15, 2003) (8 pages) doi:10.1115/1.1556402 History: Received September 01, 2001; Revised April 01, 2002; Online April 15, 2003
Copyright © 2003 by ASME
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References

Tlusty,  J., and MacNeil,  P., 1975, “Dynamics of Cutting Forces in End Milling,” CIRP Ann., 24, pp. 21–25.
Kline,  W. A., DeVor,  R. E., and Shareef,  I., 1982, “The Prediction of Surface Accuracy in End Milling,” ASME J. Eng. Ind., 104, pp. 272–278.
Montgomery,  D., and Altintas,  Y., 1989, “Mechanism of Cutting Force and Surface Generation in Dynamic Milling,” ASME J. Eng. Ind., 113, pp. 160–168.
Bao,  W. Y., and Tansel,  I. N., 2000, “Modeling Micro-End-Milling Operations. Part I: Analytical Cutting Force Model,” Int. J. Mach. Tools Manuf., 40, pp. 2155–2173.
Friedrich,  C., Coane,  P., Goettert,  J., and Gopinathin,  N., 1998, “Direct Fabrication of Deep X-Ray Lithography Masks by Micromechanical Milling,” Precis. Eng., 22(3), pp. 164–173.
Bao,  W. Y., and Tansel,  I. N., 2000, “Modeling Micro-End-Milling Operations. Part II: Tool Run-Out,” Int. J. Mach. Tools Manuf., 40, pp. 2175–2192.
Bao,  W. Y., and Tansel,  I. N., 2000, “Modeling Micro-End-Milling Operations. Part III: Influence of Tool Wear,” Int. J. Mach. Tools Manuf., 40, pp. 2193–2211.
Yuan,  Z. J., Geng,  L., and Dong,  S., 1993, “Ultraprecision Machining of SiCw/Al Composites,” CIRP Ann., 42, pp. 107–109.
Chuzhoy, L., DeVor, R. E., Kapoor, S. G., and Bammann, D. J., 2001, “Microstructure-Level Modeling of Ductile Iron Machining,” Proceedings of the ASME Manufacturing Engineering Division.
Chuzhoy, L., DeVor, R. E., Kapoor, S. G., Beaudoin, A. J., and Bammann, D. J., 2001, “Machining Model of Ductile Iron and Its Constituents. Part I: Estimation of Material Model Parameters and Their Validation,” Proceedings of the ASME Manufacturing Engineering Division.
Chuzhoy, L., DeVor, R. E., and Kapoor, S. G., 2001, “Machining Simulation of Ductile Iron and Its Constituents. Part II: Numerical Simulation and Experimental Validation of Machining,” Proceedings of the ASME Manufacturing Engineering Division.
Kapoor,  S. G., DeVor,  R. E., Zhu,  R., Gajjela,  R., Parakkal,  G., and Smithey,  D., 1998, “Development of Mechanistic Models for the Prediction of Machining Performance: Model Building Methodology,” Mach. Sci. Technol., 2, pp. 213–238.

Figures

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(a) Actual and (b) simulated microstructure of pearlitic ductile iron
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End milling of ductile iron workpiece
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(a) Actual and (b) simulated microstructure of ferritic ductile iron
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Simulated and experimental cutting forces for ferrite calibration (high feed)
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Experimental pearlitic ductile iron data (high feed)
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Simulated pearlitic ductile iron data (high feed)
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Experimental ferritic ductile iron data (low feed)
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Simulated ferritic ductile iron data (low feed)
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Experimental ferrite data (high feed)
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Experimental pearlite data (low feed)
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Simulated cutting forces for macro-milling of pearlitic ductile iron
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Microstructure variation study data

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