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Title ENHANCEMENT AND VERIFICATION OF A CUTTING FORCE MODEL FOR MICRO CUTTING
Author Slunský, Jan
Supervisor 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)
Institution Technical University of Denmark, DTU, DK-2800 Kgs. Lyngby, Denmark
Thesis level Master's thesis
Year 2007
Abstract 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.
Pages 108
Fulltext
Original PDF M_Sc_thesis_Jan_Slunsky.pdf (3.64 MB)
Admin Creation date: 2008-02-08    Update date: 2008-02-08    Source: dtu    ID: 210403    Original MXD