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TECHNICAL PAPERS

On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part II: Cutting Force Prediction

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

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906

J. Manuf. Sci. Eng 126(4), 695-705 (Feb 04, 2005) (11 pages) doi:10.1115/1.1813471 History: Received February 01, 2003; Revised March 01, 2004; Online February 04, 2005
Copyright © 2004 by ASME
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References

Vogler,  M. P., DeVor,  R. E., and Kapoor,  S. G., 2004, “Microstructure-Level Force Prediction Model for Micro-Milling of Multi-Phase Materials,” ASME J. Manuf. Sci. Eng., 126(4), pp. 695–705.
Vogler,  M. P., DeVor,  R. E., and Kapoor,  S. G., 2003, “Microstructure-Level Force Prediction Model for Micro-Milling of Multi-Phase Materials,” ASME J. Manuf. Sci. Eng., 125, pp. 202–209.
Waldorf,  D. J., DeVor,  R. E., and Kapoor,  S. G., 1998, “A Slip-Line Field for Ploughing During Orthogonal Cutting,” ASME J. Manuf. Sci. Eng., 120, pp. 693–699.
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Chuzhoy,  L., DeVor,  R. E., Kapoor,  S. G., and Bammann,  D. J., 2002, “Microstructure-Level Modeling of Ductile Iron Machining,” ASME J. Manuf. Sci. Eng., 124, pp. 162–169.
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Figures

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Illustration of chip thickness computation for (a) chip thickness less than tC,min, (b) initial chip formation, (c) chip formation continuing across tool pass boundaries, and (d) results of tool pass
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Schematic showing interference volume
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Relation of endmilling forces to orthogonal machining forces
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Shear angle as a function of average rake angle for (a) ferrite and (b) pearlite
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Flow stress as a function of chip thickness for (a) ferrite and (b) pearlite
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Experimental and predicted peak-to-valley forces for (a) ferrite, 2 μm edge radius; (b) ferrite, 5 μm edge radius; (c) pearlite, 2 μm edge radius; and (d) pearlite, 5 μm edge radius
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Experimental and predicted peak-to-valley forces for (a) ferritic DI, 2 μm edge radius; (b) ferritic DI, 5 μm edge radius; (c) pearlitic DI, 2 μm edge radius; and (d) pearlitic DI, 5 μm edge radius
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(a) Simulated and (b) experimental Y forces and spectra for pearlite test 6
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(a) Simulated and (b) experimental Y forces and spectra for pearlite test 10
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Decomposition of forces for (a) pearlite test 6 and (b) pearlite test 10
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Decomposition of forces with 1 μm runout for (a) pearlite test 6 and (b) pearlite test 10
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Y force and filtered spectrum to show effect of workpiece microstructure on force system
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Endmilling of ductile iron workpiece 1
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Illustration of chip thickness computation

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