Investigation of the Dynamics of Microend Milling—Part I: Model Development

[+] Author and Article Information
Martin B. Jun, Xinyu Liu, Richard E. DeVor, Shiv G. Kapoor

Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, 1206 West Green Street, Urbana, IL 61801

J. Manuf. Sci. Eng 128(4), 893-900 (Jan 05, 2006) (8 pages) doi:10.1115/1.2193546 History: Received May 10, 2005; Revised January 05, 2006

In microend milling, due to the comparable size of the edge radius to chip thickness, chip formation mechanisms are different. Also, the design of microend mills with features of a large shank, taper, and reduced diameter at the cutting edges introduces additional dynamics and faults or errors at the cutting edges. A dynamic microend milling cutting force and vibration model has been developed to investigate the microend milling dynamics caused by the unique mechanisms of chip formation as well as the unique microend mill design and its associated fault system. The chip thickness model has been developed considering the elastic-plastic nature in the ploughing process. A slip-line field modeling approach is taken for a cutting force model development that accounts for variations in the effective rake angle and dead metal cap. The process fault parameters associated with microend mills have been defined and their effects on chip load have been derived. Finally, a dynamic model has been developed considering the effects of both the unique microend mill design and fault system and factors that become significant at high spindle speeds including rotary inertia and gyroscopic moments.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Chip load considering the effect of elastic recovery for case 1

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Figure 2

Chip load considering the effect of elastic recovery for cases 2 and 3

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Figure 3

Proposed slip-line field for chip formation forces with variable dead metal cap size and its associated hodograph

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Figure 4

Proposed slip-line field for ploughing/rubbing without chip formation with its associated hodograph

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Figure 5

Microend mill with associated errors

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Figure 6

Coordinate frames for the microend mill in the presence of process faults

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Figure 7

Discretization of the microend mill

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Figure 8

Positions of microend mill for chip thickness calculation




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