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Research Papers

A New Mechanistic Approach for Micro End Milling Force Modeling

[+] Author and Article Information
Martin B. G. Jun, Chanseo Goo

Department of Mechanical Engineering,  University of Victoria, Victoria, BC, V8W 3P6

Mohammad Malekian, Simon Park

Department of Mechanical Engineering,  University of Calgary, Calgary, AB, T2N 1N4

J. Manuf. Sci. Eng 134(1), 011006 (Jan 12, 2012) (9 pages) doi:10.1115/1.4005429 History: Received May 17, 2010; Revised October 21, 2011; Published January 12, 2012; Online January 12, 2012

This paper investigates the mechanistic modeling of micro end milling forces, with consideration of the effects of plowing, elastic recovery, effective rake angle, and flank face rubbing. Two different mechanistic models are developed for shearing- and plowing-dominant regimes. Micro end milling experiments are conducted to validate the model for Aluminum 6061; and, the model appropriately predicts force profiles for a wide range of feed rates, and prediction of the root mean square (RMS) values of the resultant forces is, on average, within a 12% error. The study of the model shows that plowing and rubbing force contributions are significant, especially at low feed rates. The edge radius is found to have a significant effect on plowing and rubbing force components and the effective rake angle, which indicates that it is important to maintain a low edge radius to reduce micro end milling forces.

FIGURES IN THIS ARTICLE
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Copyright © 2012 by American Society of Mechanical Engineers
Topics: Force , Milling , Cutting , Thickness
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Figures

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Figure 1

Chip formation forces on tools with a finite edge radius

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Figure 2

Elemental effective rake angles for elements on a rounded edge

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Figure 3

Plowing/rubbing forces without chip formation

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Figure 4

(a) Geometrical parameters during a scratch test and (b) equivalent semi-apical angle in micro end milling

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Figure 5

(a) CNC micro machine and (b) SEM pictures of the tool

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Figure 6

Comparison of the RMS data between experiment and simulation

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Figure 7

Switchover between two cutting mechanisms during micro end milling

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Figure 8

Comparison of force profiles between the simulation and the experiment

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Figure 9

Comparison of force frequency contents between the simulation and the experiment

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Figure 10

Comparison of force profiles between the experiment and the simulation, with and without considering plowing force components

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Figure 11

Peak-to-valley values of the resultant force against feed rates at different edge radii

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Figure 12

Study of effective rake angle changes at different (a) rake angles and (b) edge radii

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Figure 13

Effect of elastic recovery at different feed rates

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