||ENHANCEMENT AND VERIFICATION OF A CUTTING FORCE MODEL FOR MICRO CUTTING
||Hansen, Hans Nørgaard (Institut for Produktion og Ledelse, Danmarks Tekniske Universitet, DTU, DK-2800 Kgs. Lyngby, Denmark)
Bissacco, Giuliano (Institut for Produktion og Ledelse, Danmarks Tekniske Universitet, DTU, DK-2800 Kgs. Lyngby, Denmark)
||Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark
||This thesis is aimed at developing the mathematical model for cutting force
prediction in micro end-milling operation. The development of quantitatively reliable
predictive models is driven by the need to optimize the economic performance of
machining operations and particularly by specific demands in micro-cutting operations
corresponding to the tool deflections and its breakage.
After the introduction to the world of micro-manufacturing, the modelling of
cutting processes is shortly described. The unified mechanics of cutting approach to
the prediction of forces in milling operations is adopted and extended with numerical
calculation of the chip flow angle instead of using the Stabler rule. Also tool run-out is
considered and implemented into the model.
The unified mechanics of cutting approach introduces the edge force
coefficients in addition to the cutting force coefficients. This method eliminates the
need for the experimental calibration of each tool geometry and relies just on an
experimentally determined orthogonal cutting data, which are obtained in the turning
experiments of the aluminium 6082 T6 and the carbon steel UHB 11.
The mathematical model with the cutting quantities implemented from the
turning experiments is evaluated in terms of micro milling experiments on
conventional CNC milling machine with attached high speed spindle. A method for the
axial depth of cut control is required by such a machine, when using the end mills of
200μm, and therefore it is shortly described here.
Creation date: 2008-02-08
Update date: 2008-02-08