Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling

doi:10.3390/mi13111805

	Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling
	Gao, Shuaishuai 2; Duan, Xianyin 3; Zhu, Kunpeng 1; Zhang, Yu 3
刊名	MICROMACHINES
	2022-11-01
卷号	13
关键词	cutting force mechanical modeling micro-end milling tool edge radius tool flank wear tool runout
DOI	10.3390/mi13111805
通讯作者	Duan, Xianyin(xyduan@wust.edu.cn) ; Zhu, Kunpeng(zhukp@iamt.ac.cn)
英文摘要	Accurate cutting force prediction is crucial in improving machining precision and surface quality in the micro-milling process, in which tool wear and runout are essential factors. A generic analytic cutting force model considering the effect of tool edge radius on tool flank wear and tool runout in the micro-end milling process is proposed. Based on the analytic modeling of the cutting part of the cutting edge in the end face of the micro-end mill bottom, the actual radius model of the worn tool is established, considering the tool edge radius and tool flank wear. The tool edge radius, tool wear, tool runout, trochoidal trajectories of the current cutting edge, and all cutting edges in the previous cycle are comprehensively considered in the instantaneous uncut chip thickness calculation and the cutter-workpiece engagement determination. The cutting force coefficient model including tool wear is established. A series of milling experiments are performed to verify the accuracy and effectiveness of the proposed cutting force model. The results show that the predicted cutting forces are in good agreement with the experimental cutting forces, and it is necessary to consider tool wear in the micro-milling force modeling. The results indicate that tool wear has a significant influence on the cutting forces and cutting force coefficients in the three directions, and the influences of tool wear on the axial cutting force and axial force coefficient are the largest, respectively. The proposed cutting force model can contribute to real-time machining process monitoring, cutting parameters optimization and ensuring machining quality.
资助项目	National Natural Science Foundation of China[52005201]
WOS关键词	UNDEFORMED CHIP THICKNESS ; PART II ; PREDICTION ; OPERATIONS ; STEEL
WOS研究方向	Chemistry ; Science & Technology - Other Topics ; Instruments & Instrumentation ; Physics
语种	英语
出版者	MDPI
WOS记录号	WOS:000881112600001
资助机构	National Natural Science Foundation of China
内容类型	期刊论文
源URL	[http://ir.hfcas.ac.cn:8080/handle/334002/130142]
专题	中国科学院合肥物质科学研究院
通讯作者	Duan, Xianyin; Zhu, Kunpeng
作者单位	1.Chinese Acad Sci, Hefei Inst Phys Sci, Inst Intelligent Machines, Hefei 230031, Peoples R China 2.Cent China Normal Univ, Sch Math & Stat, Wuhan 430079, Peoples R China 3.Wuhan Univ Sci & Technol, Minist Educ, Key Lab Met Equipment & Control Technol, Wuhan 430081, Peoples R China
推荐引用方式 GB/T 7714	Gao, Shuaishuai,Duan, Xianyin,Zhu, Kunpeng,et al. Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling[J]. MICROMACHINES,2022,13.
APA	Gao, Shuaishuai,Duan, Xianyin,Zhu, Kunpeng,&Zhang, Yu.(2022).Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling.MICROMACHINES,13.
MLA	Gao, Shuaishuai,et al."Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling".MICROMACHINES 13(2022).