A Static Model of Chip Formation in Microscale Milling

[+] Author and Article Information
Chang-Ju Kim, J. Rhett Mayor, Jun Ni

S.M. Wu Manufacturing Research Center, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

J. Manuf. Sci. Eng 126(4), 710-718 (Feb 04, 2005) (9 pages) doi:10.1115/1.1813475 History: Received February 17, 2004; Revised July 22, 2004; Online February 04, 2005
Copyright © 2004 by ASME
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Schematic of the milling process
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Interaction between the cutting edge and the workpiece
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Consecutive chip formation (h(θ0)>hm)
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Intermittent chip formation (h(θ0)<hm)
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Calculated variation of period as a function of position angle under an assumption of hm=3 μm
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Measured and transformed cutting forces (Exp. I, ft=3 μm)
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Cutting forces versus number of tooth passes (Exp. I, θ=90°)
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Cutting forces versus number of tooth passes (Exp. II, θ=90 deg)
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Cutting forces versus number of tooth passes (Exp. III, θ=90 deg)
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Measured cutting forces as a function of the engagement
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Graphs of the periodicity in force fluctuation with respect to n, which demonstrate that the period decreases with ft at any position angle
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Feed per tooth and the minimum chip thickness



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