Model-Based Analysis of the Surface Generation in Microendmilling—Part I: Model Development

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

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

J. Manuf. Sci. Eng 129(3), 453-460 (Nov 13, 2006) (8 pages) doi:10.1115/1.2716705 History: Received April 28, 2006; Revised November 13, 2006

This paper presents the development of models that describe the surface-generation process for microendmilling. The surface-generation models for the sidewall and floor surfaces consist of deterministic and stochastic models. In the sidewall surface-generation model, the deterministic model characterizes the surface topography generated from the relative motion between the major cutting edge and the workpiece material. The model includes the effects of the process kinematics, dynamics, tool edge serration, and process faults (e.g., tool tip runout). The stochastic model predicts the increased surface roughness generated from ploughing due to the significant tool edge radius effect. In the floor surface-generation model, the deterministic model characterizes the three-dimensional surface topography over the entire floor surface and considers the effects of the minimum chip thickness, the elastic recovery, and the transverse vibration. The variation of the ploughing amount across the swept arc of the cutter due to the varying chip load conditions is considered in the stochastic model.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Edge radius and edge serration of microendmill

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Figure 2

Edge serration geometry model

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Figure 7

Computation of the areas of ploughing zone Ap and cutting zone Ac at different chipload tc

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Figure 8

Illustration of floor surface generation model: (a) Representation of tool path and workpiece surface and (b) interpolation of the tool location within the sweeping volume

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Figure 3

Process geometry of the sidewall surface generation considering the edge serration

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Figure 4

Surface generation considering effect of elastic recovery

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Figure 5

Trajectory of the end cutting edge on the floor surface and detailed view of selected regions

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Figure 6

(a) Local chip thickness computation and the ploughing/cutting zones and (b) geometric model of floor surface profile considering elastic recovery





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