End Milling of Elastomers—Fixture Design and Tool Effectiveness for Material Removal

[+] Author and Article Information
Albert J. Shih

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109  

Mark A. Lewis, John S. Strenkowski

Department of Mechanical and Aerospace Engineering, North Carolina State University, Raleigh, NC 27695-7910

J. Manuf. Sci. Eng 126(1), 115-123 (Mar 18, 2004) (9 pages) doi:10.1115/1.1616951 History: Received April 01, 2002; Revised May 01, 2003; Online March 18, 2004
Copyright © 2004 by ASME
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Results of the preliminary elastomer end milling test that failed to make a clear-cut groove on an elastomer workpiece with steel cable reinforcement (a) side view and (b) front view
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Up-, down-, and mixed-cut end mills, (a) up-cut end mill, (b) down-cut end mill, (c) mixed-cut end mill, (d) up-cut end smilling setup, (e) down-cut end milling setup, and (f ) mixed-cut end milling setup
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The deformation of elastomer workpiece while machining using an up-cut end mill
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Fixture for end milling of elastomer (a) base and top plate with grooves and (b) top view of the fixture with the elastomer workpiece in place
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Three-dimensional finite element meshes and boundary conditions for the elastomer workpiece machined by 3.18 mm diameter end mill
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Three-dimensional finite element meshes for the elastomer workpiece machined by end milling with (a) 6.35 mm and (b) 12.7 mm diameter tools
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Loading on the finite element analysis (a) assuming the traction stress is uniformly distributed on the surface of an element in the Z-direction, (b) the consistent nodal load at the eight nodes on the surface of a hexahedral element with the element resultant force, Fe, on the surface, and (c) assembled force vectors on the quarter cylinder surface
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Thirteen milling tools (router bits) used in the elastomer machining experiments (HSS: High Speed Steel, Carbide: WC in Co matrix)
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Examples of milled groove condition levels for an elastomer workpiece
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Grooves machined in Experiments I and III
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Some grooves machined in Experiments V and VII



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