Special Section: Micromanufacturing

A Mechanistic Model of Cutting Forces in Micro-End-Milling With Cutting-Condition-Independent Cutting Force Coefficients

[+] Author and Article Information
Han Ul Lee

Department of Mechanical Engineering, Pohang University of Science and Technology, San 31, Hyoja-dong, Nam-gu, Pohang, Gyungbuk 790-784, South Korea

Dong-Woo Cho1

Department of Mechanical Engineering, Pohang University of Science and Technology, San 31, Hyoja-dong, Nam-gu, Pohang, Gyungbuk 790-784, South Koreadwcho@postech.ac.kr

Kornel F. Ehmann

Department of Mechanical Engineering, Northwestern University, Evanston, IL 60208


Corresponding author.

J. Manuf. Sci. Eng 130(3), 031102 (May 05, 2008) (9 pages) doi:10.1115/1.2917300 History: Received January 18, 2007; Revised December 24, 2007; Published May 05, 2008

Complex three-dimensional miniature components are needed in a wide range of industrial applications from aerospace to biomedicine. Such products can be effectively produced by micro-end-milling processes that are capable of accurately producing high aspect ratio features and parts. This paper presents a mechanistic cutting force model for the precise prediction of the cutting forces in micro-end-milling under various cutting conditions. In order to account for the actual physical phenomena at the edge of the tool, the components of the cutting force vector are determined based on the newly introduced concept of the partial effective rake angle. The proposed model also uses instantaneous cutting force coefficients that are independent of the end-milling cutting conditions. These cutting force coefficients, determined from measured cutting forces, reflect the influence of the majority of cutting mechanisms involved in micro-end-milling including the minimum chip-thickness effect. The comparison of the predicted and measured cutting forces has shown that the proposed method provides very accurate results.

Copyright © 2008 by American Society of Mechanical Engineers
Topics: Force , Cutting , Milling , Thickness
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Figure 1

Cutter geometry, coordinate system, and unit vectors on the rake surface (9)

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Figure 2

Schematic of the cutter’s edge and of the partial effective rake angle for two different points, c1 and c2, within the chip

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Figure 3

Partial effective rake angle with respect to chip position

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Figure 4

Schematic of the sliced uncut chip area

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Figure 9

Comparison between measured and predicted cutting forces: (a) Test 1, (b) Test 4, (c) Test 7, (d) Test 8, (e) Test 9, (f) Test 10, (g) Test 11, and (h) Test 13

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Figure 5

Measured y-directional cutting forces for small values of the feed per tooth: (a) 0.05μm/tooth, (b) 0.1μm/tooth, and (c) 0.5μm/tooth

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Figure 6

Developed three-axis miniature machine tool

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Figure 7

Calculated and fitted cutting force coefficients: (a) ln(Kn) with respect to the instantaneous uncut chip thickness, (b) ln(Kf) with respect to the instantaneous uncut chip thickness, and (c) θc with respect to the angular position of the cutter

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Figure 8

SEM image of the cutter edge and the determined edge radius of the cutter



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