The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics
In the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual...
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2022-03-01
|
| Series: | Machines |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2075-1702/10/3/217 |
| _version_ | 1827628445175119872 |
|---|---|
| author | Peng Wang Qingshun Bai Kai Cheng Liang Zhao Hui Ding |
| author_facet | Peng Wang Qingshun Bai Kai Cheng Liang Zhao Hui Ding |
| author_sort | Peng Wang |
| collection | DOAJ |
| description | In the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual trochoidal trajectories of the cutting edge on micro-milling forces should also be considered comprehensively. In this paper, the tool runout error in the micro-milling process is first analysed, and an instantaneous undeformed chip thickness model is established considering the runout error. On this basis, the dynamic deformation of the micro-cutting tool and thin-walled micro-part is studied, and an instantaneous, undeformed, chip-thickness model is proposed with the consideration of both the runout error and dynamic deformation. The dynamic parameters of the machining system are obtained using the receptance coupling method. Finally, thin-walled micro-part machining experiments are carried out, and the obtained results of micro-milling force simulation based on the proposed model are compared with the experimental results. The results indicate that the micro-milling force modelling, by taking the influence of machining dynamics into account, has better prediction accuracy, and the difference between the predicted resultant forces and the experimental results is less than 11%. |
| first_indexed | 2024-03-09T13:32:41Z |
| format | Article |
| id | doaj.art-f7b0552041cc4fd1890a7d210b3eebb9 |
| institution | Directory Open Access Journal |
| issn | 2075-1702 |
| language | English |
| last_indexed | 2024-03-09T13:32:41Z |
| publishDate | 2022-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Machines |
| spelling | doaj.art-f7b0552041cc4fd1890a7d210b3eebb92023-11-30T21:16:30ZengMDPI AGMachines2075-17022022-03-0110321710.3390/machines10030217The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining DynamicsPeng Wang0Qingshun Bai1Kai Cheng2Liang Zhao3Hui Ding4School of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin 150001, ChinaSchool of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin 150001, ChinaDepartment of Mechanical and Aerospace Engineering, Brunel University London, Uxbridge UB8 3PH, UKSchool of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin 150001, ChinaSchool of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin 150001, ChinaIn the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual trochoidal trajectories of the cutting edge on micro-milling forces should also be considered comprehensively. In this paper, the tool runout error in the micro-milling process is first analysed, and an instantaneous undeformed chip thickness model is established considering the runout error. On this basis, the dynamic deformation of the micro-cutting tool and thin-walled micro-part is studied, and an instantaneous, undeformed, chip-thickness model is proposed with the consideration of both the runout error and dynamic deformation. The dynamic parameters of the machining system are obtained using the receptance coupling method. Finally, thin-walled micro-part machining experiments are carried out, and the obtained results of micro-milling force simulation based on the proposed model are compared with the experimental results. The results indicate that the micro-milling force modelling, by taking the influence of machining dynamics into account, has better prediction accuracy, and the difference between the predicted resultant forces and the experimental results is less than 11%.https://www.mdpi.com/2075-1702/10/3/217thin-walled micro-partsmicro-millingcutting force modelmachining dynamicscutting tool runout |
| spellingShingle | Peng Wang Qingshun Bai Kai Cheng Liang Zhao Hui Ding The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics Machines thin-walled micro-parts micro-milling cutting force model machining dynamics cutting tool runout |
| title | The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics |
| title_full | The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics |
| title_fullStr | The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics |
| title_full_unstemmed | The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics |
| title_short | The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics |
| title_sort | modelling and analysis of micro milling forces for fabricating thin walled micro parts considering machining dynamics |
| topic | thin-walled micro-parts micro-milling cutting force model machining dynamics cutting tool runout |
| url | https://www.mdpi.com/2075-1702/10/3/217 |
| work_keys_str_mv | AT pengwang themodellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT qingshunbai themodellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT kaicheng themodellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT liangzhao themodellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT huiding themodellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT pengwang modellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT qingshunbai modellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT kaicheng modellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT liangzhao modellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics AT huiding modellingandanalysisofmicromillingforcesforfabricatingthinwalledmicropartsconsideringmachiningdynamics |