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Research Papers

Chatter Stability Model of Micro-Milling With Process Damping

[+] Author and Article Information
Yusuf Altintas

e-mail: Altintas@mech.ubc.ca
Manufacturing Automation Laboratory,
University of British Columbia,
2054-6250 Applied Science Lane,
Vancouver, BC, V6T 1Z4, Canada

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 10, 2012; final manuscript received February 18, 2013; published online May 24, 2013. Assoc. Editor: Burak Ozdoganlar.

J. Manuf. Sci. Eng 135(3), 031011 (May 24, 2013) (9 pages) Paper No: MANU-12-1141; doi: 10.1115/1.4024038 History: Received May 10, 2012; Revised February 18, 2013

This paper presents the prediction of cutting forces and chatter stability of micro-milling operations from the material's constitutive flow stress and structural dynamics of the micro-end mill. The cutting force coefficients are identified either using previously presented slip-line field or finite element methods by considering the effects of chip size, cutting edge radius, rake angle and cutting speed. The process damping caused by the plowing of round edge is modeled by finite element method. The frequency response function of the fragile micro-mill is measured through specially devised piezo actuator mechanism. Dynamic model of micro-milling with the velocity dependent process damping mechanism is presented, and the chatter stability is predicted in frequency domain. The proposed models have been experimentally verified in micro-milling of AISI 1045 steel.

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References

Altintas, Y., 2012, Manufacturing Automation, Cambridge University, Cambridge, UK, Chap. 4.
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Altintas, Y., and Jin, X., 2011, “Mechanics of Micro-Milling With Round Edge Tools,” CIRP Ann., 60(1), pp. 77–80. [CrossRef]
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Filiz, S., and Ozdoganlar, O. B., 2008, “Microendmill Dynamics Including the Actual Fluted Geometry and Setup Errors—Part II: Model Validation and Application,” ASME J. Manuf. Sci. Eng., 130(3), p. 031120. [CrossRef]
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Altintas, Y., Eynian, M., and Onozuka, H., 2008, “Identification of Dynamic Cutting Force Coefficients and Chatter Stability With Process Damping,” CIRP Ann., 57(1), pp. 371–374. [CrossRef]
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Figures

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Fig. 1

Dynamic micro-milling system

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Fig. 2

Cutting forces predicted by slip-line field model (material: AISI 1045 steel. A = 553.1 MPa, B = 600.8 MPa, C = 0.013, n = 0.234, m = 1, Tm = 1460 °C and Tr = 25 °C)

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Fig. 3

Comparison of micro-milling forces predicted by slip-line field model and experiment

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Fig. 4

Schematic of single degree of freedom orthogonal cutting: (a) micro-cutting with tool edge radius; (b) macro-cutting with tool wear

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Fig. 5

FE simulation of displacement, velocity and contact force in orthogonal cutting of AISI 1045 with a tool having 80 μm flank wear

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Fig. 6

Measurement of tool edge geometry under optical microscope

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Fig. 7

Measured and curve-fitted FRF of micro-mill at tool tip

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Fig. 8

Experimental setup for micro-milling test

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Fig. 9

Predicted stability lobes with process damping effect. All four modes of micro-mill are considered.

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Fig. 10

(a) Predicted and experimentally evaluated chatter stability lobes; (b) chatter at n=45,450rev/min,a=30 μm; (c) stable at n=54,600rev/min,a=50 μm

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