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.
Issue Section:
Research Papers
References
1.
Altintas
, Y.
, 2012
, Manufacturing Automation
, Cambridge University
, Cambridge, UK
, Chap. 4.2.
Mascardelli
, B. A.
, Park
, S. S.
, and Freiheit
, T.
, 2008
, “Substructure Coupling of Microend Mills to Aid in the Suppression of Chatter
,” ASME J. Manuf. Sci. Eng.
, 130
(1
), p. 011010
.10.1115/1.28161043.
Jin
, X.
, and Altintas
, Y.
, 2011
, “Slip-Line Field Model of Micro-Cutting Process With Round Tool Edge Effect
,” J. Mater. Process. Technol.
, 211
(3
), pp. 339
–355
.10.1016/j.jmatprotec.2010.10.0064.
Jin
, X.
, and Altintas
, Y.
, 2012
, “Prediction of Micro-Milling Forces With Finite Element Method
,” J. Mater. Process. Technol.
, 212
(3
), pp. 542
–552
.10.1016/j.jmatprotec.2011.05.0205.
Altintas
, Y.
, and Jin
, X.
, 2011
, “Mechanics of Micro-Milling With Round Edge Tools
,” CIRP Ann.
, 60
(1
), pp. 77
–80
.10.1016/j.cirp.2011.03.0846.
Afazov
, S. M.
, Ratchev
, S. M.
, Segal
, J.
, and Popov
, A. A.
, 2012
, “Chatter Modelling in Micro-Milling by Considering Process Nonlinearities
,” Int. J. Mach. Tools Manuf.
, 56
, pp. 28
–38
.10.1016/j.ijmachtools.2011.12.0107.
Filiz
, S.
, and Ozdoganlar
, O. B.
, 2008
, “Microendmill Dynamics Including the Actual Fluted Geometry and Setup Errors—Part I: Model Development and Numerical Solution
,” ASME J. Manuf. Sci. Eng.
, 130
(3
), p. 031119
.10.1115/1.29173218.
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
.10.1115/1.29363799.
Wallace
, P. W.
, and Andrew
, C.
, 1965
, “Machining Forces: Some Effects of Tool Vibration
,” J. Mech. Eng. Sci.
, 7
, pp. 152
–162
.10.1243/JMES_JOUR_1965_007_023_0210.
Chiou
, R. Y.
, and Liang
, S. Y.
, 1998
, “Chatter Stability of a Slender Cutting Tool in Turning With Wear Effect
,” Int. J. Mach. Tools Manuf.
, 38
(4
), pp. 315
–327
.10.1016/S0890-6955(97)00079-511.
Sisson
, T. R.
, and Kegg
, R. L.
, 1969
, “An Explanation of Low-Speed Chatter Effects
,” ASME J. Eng. Industry
, 91
(4
), pp. 951
–958
.10.1115/1.359177812.
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
.10.1016/j.cirp.2008.03.04813.
Eynian
, M.
, and Altintas
, Y.
, 2009
, “Chatter Stability of General Turning Operations With Process Damping
,” ASME J. Manuf. Sci. Eng.
, 131
(4
), p. 041005
.10.1115/1.315904714.
Budak
, E.
, and Tunc
, L. T.
, 2009
, “A New Method for Identification and Modeling of Process Damping in Machining
,” ASME J. Manuf. Sci. Eng.
, 131
(5
), p. 051019
.10.1115/1.400017015.
Rahnama
, R.
, Sajjadi
, M.
, and Park
, S. S.
, 2009
, “Suppression of Chatter in Micro Milling With Process Damping
,” J. Mater. Process. Technol.
, 209
, pp. 5766
–5776
.10.1016/j.jmatprotec.2009.06.00916.
Tobias
, S. A.
, and Fishwick
, W.
, 1958
, “Theory of Regenerative Machine Tool Chatter
,” The Engineer
, 205
, pp. 199
–203.17.
Johnson
, G. R.
, and Cook
, W. H.
, 1983
, “A Constitutive Model and Data for Metals Subjected to Large Strains High Strain Rates and High Temperatures
,” Proceedings of the 7th International Symposium on Ballistics, The Hague, Netherlands, Vol. 21, pp. 541
–547
.18.
Jaspers
, S. P. F. C.
, and Dautzenberg
, J. H.
, 2002
, “Material Behavior in Conditions Similar to Metal Cutting: Flow Stress in the Primary Shear Zone
,” J. Mater. Process. Technol.
, 122
, pp. 322
–330
.10.1016/S0924-0136(01)01228-619.
Altintas
, Y.
, and Park
, S. S.
, 2004
, “Dynamic Compensation of Spindle-Integrated Force Sensors
,” CIRP Ann.
, 53
(1
), pp. 305
–308
.10.1016/S0007-8506(07)60703-320.
ABAQUS
, 2008
, Theory and Analysis User’s Manual, Version 6.8-3.21.
Altintas
, Y.
, and Budak
, E.
, 1995
, “Analytical Prediction of Stability Lobes in Milling
,” CIRP Ann.
, 44
(1
), pp. 357
–362
.10.1016/S0007-8506(07)62342-722.
23.
Landers
, R. G.
, and Ulsoy
, A. G.
, 2008
, “Nonlinear Feed Effect in Machining Chatter Analysis
,” ASME J. Manuf. Sci. Eng.
, 130
(1), p. 011017
.10.1115/1.2783276Copyright © 2013 by ASME
You do not currently have access to this content.
