Development and experimental validation of a mechanistic model of cutting forces in micro- ball end milling of full slots

doi:10.1080/10910344.2017.1415932

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Development and experimental validation of a mechanistic model of cutting forces in micro- ball end milling of full slots

Journal Article•DOI•

Development and experimental validation of a mechanistic model of cutting forces in micro- ball end milling of full slots

M. Baburaj¹, Amitava Ghosh¹, M.S. Shunmugam¹•Institutions (1)

Indian Institute of Technology Madras¹

30 Apr 2018-Machining Science and Technology (Taylor & Francis)-Vol. 22, Iss: 5, pp 787-810

TL;DR: In this paper, a mechanistic model of cutting forces is developed with a novel approach to arrive at the cutting edge geometry as well as the cutting mechanics, and the geometry of cutting edges is described.

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Abstract: In the present work, a mechanistic model of cutting forces is developed with a novel approach to arrive at the cutting edge geometry as well as the cutting mechanics. The geometry of cutting elemen...

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Journal Article•DOI•

The influence of tool-path strategies and cutting parameters on cutting forces, tool wear and surface quality in finish milling of Aluminium 7075 curved surface

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Rahul A. Mali¹, Rentala Aiswaresh¹, T.V.K. Gupta¹•Institutions (1)

Visvesvaraya National Institute of Technology¹

01 May 2020-The International Journal of Advanced Manufacturing Technology

TL;DR: In this article, a parametric analysis is performed by conducting the statistically designed experiments with 3D offset strategy to highlight the input-output correlations in curved surface milling and the results show that along with the magnitude of the force, a time lag and nature of force profile are equally significant in determining the tool wear and surface roughness.

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Abstract: The curved parts of Aluminium 7075 alloy are extensively used in automotive and aircraft structures. In curved surface milling, the tool-workpiece contact changes continuously varying effective tool radius, active cutting speed and cutting forces all the time during machining. These variations lead to a change in metal removal mechanism from shearing to ploughing and vice-versa that determines the final product quality. In the present work, the tool-path strategies are investigated in the first phase wherein 3D offset found to be the best finishing strategy. Latter, the parametric analysis is performed by conducting the statistically designed experiments with 3D offset strategy to highlight the input-output correlations. The Khattree–Naik’s equation/plot is used to analyse the multivariate data in milling and accordingly the better input parameters are selected. A ball-end tool imparting the entire tool face and cutting the surface from all-around with consistent cutting conditions enhances the tool life with a better finish. The results show that along with the magnitude of the force, a time lag (Δt) and nature of force profile are equally significant in determining the tool wear and surface roughness.

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10 citations

Journal Article•DOI•

Cutter-workpiece engagement calculation in 3-axis ball end milling considering cutter runout

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Sai Lotfi, Belguith Rami¹, Baili Maher¹, Dessein Gilles¹, Bouzid Wassila - Show less +1 more•Institutions (1)

University of Toulouse¹

01 May 2019-Journal of Manufacturing Processes

TL;DR: In this paper, an analytical model was proposed to calculate the (CWE) region by determining the cutting instantaneous flute entry and exit angles, which were calculated according to the heights of axial depth of cut.

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8 citations

Experimental Investigation in Micro Bali-End Milling of Hardened Steel

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Berenger, Escolle, Michael, Fontaine, Alexandre, Gilbin, Sebastien, Thibaud, Philippe, Picart - Show less +6 more

01 Jan 2015

TL;DR: In this article, a micro-milling of a hardened tool steel with micro ball-end milling is studied, and the results allow highlighting some cutting, wear and dynamical phenomena related to the process.

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Abstract: The study focuses on micro-milling of a hardened tool steel with micro ball-end mills. The purpose is to observe the capability of a set of these mills to machine hard steels used for tooling applications. Different cutting configurations are here tested in order to evaluate their performance and finally enhance their design in this context. Experimental data, in terms of cutting forces, surfaces integrity and machining errors, is obtained from machining tests on a 40NiCrMo16 hardened steel with 0.5 mm diameter coated tungsten carbide micro-tools. The results allow highlighting some cutting, wear and dynamical phenomena related to the process. They are mainly associated to the types of mill and cutting conditions, as feed or tool/surface inclination. In this paper, the tool geometry and its dynamical behavior are mainly discussed.

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7 citations

Journal Article•DOI•

Experimental and theoretical investigation on cutting forces in off-centre micro ball end milling

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M. Baburaj¹, Amitava Ghosh¹, M.S. Shunmugam¹•Institutions (1)

Indian Institute of Technology Madras¹

01 Nov 2018-Cirp Journal of Manufacturing Science and Technology

TL;DR: In this paper, both down and up off-centre milling experiments are conducted on edges of steps created on a test piece, and the amplitudes of predicted forces match well with experimental values and the deviations in the experimental values arise out of micro level unevenness in the step edge.

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Abstract: Free-form surfaces and micro features are finish machined by a micro ball end mill by removing steps left behind by flat end mill in the previous operation. For effective machining, off-centre ball end milling is employed in such a way that rubbing zone near ball tip is avoided. After confirming the limits of angular immersion from full-slot experimental results, both down and up off-centre milling experiments are conducted on edges of steps created on a test piece. The micro milling forces in off-centre mode are also investigated theoretically using a mechanistic model that considers the geometry of micro ball end mill and basic mechanics of cutting. The amplitudes of predicted forces match well with experimental values and the deviations in the experimental values arise out of micro level unevenness in the step edge. The up milling with lower transverse force is found to be more suitable for machining of thin features.

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6 citations

Journal Article•DOI•

A Prediction Model of Cutting Force about Ball End Milling for Sculptured Surface

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Wenping Mou¹, Shaowei Zhu, Menghao Zhu², Lei Han², Lei Jiang² - Show less +1 more•Institutions (2)

Nanjing University of Aeronautics and Astronautics¹, Southwest Jiaotong University²

11 Mar 2020-Mathematical Problems in Engineering

TL;DR: A prediction model of cutting force is realized with microelement cutting theory and is suitable for sculptured surface machining with arbitrary tool posture and feed direction and has good adaptability to the variable tool axis relative to the machining surface.

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Abstract: Cutting force prediction is very important to optimize machining parameters and monitor machining state. In order to predict cutting force of sculptured surface machining with ball end mill accurately, tool posture, cutting edge, contact state between cutter, and workpiece are studied. Firstly, an instantaneous motion model of ball end mill for sculptured surface is established. The instantaneous milling coordinate system and instantaneous tool coordinate system are defined to describe the position and orientation of tool, and the transformation matrix between coordinate systems is derived. Secondly, by solving three boundaries around engagement of cutter and workpiece, a cutter-workpiece engagement model related to tool posture, milling parameters, and tool path is established. It has good adaptability to the variable tool axis relative to the machining surface. Finally, an algorithm of thickness about an instantaneous undeformed chip is researched, and a prediction model of cutting force is realized with microelement cutting theory. Also, the model is suitable for sculptured surface machining with arbitrary tool posture and feed direction. The accuracy of the proposed prediction model was verified by a series of experiments.

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5 citations

Cites background from "Development and experimental valida..."

...It is an effective indicator for monitoring the machining process [1]....
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References

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Journal Article•DOI•

Microtubule nucleation by γ-tubulin complexes

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Justin M. Kollman¹, Andreas Merdes², Lionel Mourey², David A. Agard¹•Institutions (2)

University of California, San Francisco¹, Centre national de la recherche scientifique²

01 Nov 2011-Nature Reviews Molecular Cell Biology

TL;DR: The first crystallographic analysis of a non-γ-tubulin γTuRC component has resulted in a new appreciation of the relationships among all γ TuRC proteins, leading to a refined model of their organization and function.

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Abstract: Microtubule nucleation is regulated by the γ-tubulin ring complex (γTuRC) and related γ-tubulin complexes, providing spatial and temporal control over the initiation of microtubule growth. Recent structural work has shed light on the mechanism of γTuRC-based microtubule nucleation, confirming the long-standing hypothesis that the γTuRC functions as a microtubule template. The first crystallographic analysis of a non-γ-tubulin γTuRC component (γ-tubulin complex protein 4 (GCP4)) has resulted in a new appreciation of the relationships among all γTuRC proteins, leading to a refined model of their organization and function. The structures have also suggested an unexpected mechanism for regulating γTuRC activity via conformational modulation of the complex component GCP3. New experiments on γTuRC localization extend these insights, suggesting a direct link between its attachment at specific cellular sites and its activation.

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3,494 citations

Book•

The Machining of Metals

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E. J. A. Armarego, R. H. Brown

01 Jan 1969

518 citations

"Development and experimental valida..." refers methods in this paper

...In the current model, cutting force coefficients due to shearing are estimated from the model proposed by Armarego and Brown (1969) and Altintas (2012)....
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Journal Article•DOI•

Prediction of ball-end milling forces from orthogonal cutting data

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P. Lee¹, Yusuf Altintas¹•Institutions (1)

University of British Columbia¹

01 Sep 1996-International Journal of Machine Tools & Manufacture

TL;DR: In this paper, the fundamental cutting parameters, the yield shear stress, average friction coefficient on the rake face and shear angle are measured from a set of orthogonal cutting tests at various cutting speeds and feeds.

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Abstract: The mechanics of cutting with helical ball-end mills are presented. The fundamental cutting parameters, the yield shear stress, average friction coefficient on the rake face and shear angle are measured from a set of orthogonal cutting tests at various cutting speeds and feeds. The cutting forces are separated into edge or ploughing forces and shearing forces. The helical flutes are divided into small differential oblique cutting edge segments. The orthogonal cutting parameters are carried to oblique milling edge geometry using the classical oblique transformation method, where the chip flow angle is assumed to be equal to the local helix angle. The cutting force distribution on the helical ball-end mill flutes is accurately predicted by the proposed method, and the model is validated experimentally and statistically by conducting more than 60 ball-end milling experiments.

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383 citations

"Development and experimental valida..." refers background or methods in this paper

...Width of cut db corresponding to the elemental cutting edge is obtained from the geometrical relation (Lee and Altintas, 1996; Armarego et al., 2002) shown in Figure 2b....
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...Elemental cutting forces are resolved into global co-ordinate forces using a transformationmatrix [T] (Lee and Altintas, 1996; Ozturk and Budak, 2007; Tuysuz et al., 2013)....
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...…( R (z) r ) (8) R(z) = √ r2 − (r − z)2 (9) z = rδ cotαc (10) Width of cut db corresponding to the elemental cutting edge is obtained from the geometrical relation (Lee and Altintas, 1996; Armarego et al., 2002) shown in Cutting forces in feed (x), transverse (y) and axial (z) directions on the…...
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...The slope at any point on the cutting edge is taken to vary according to the radii ratio of the slope at cylindrical part, namely tangent of global helix angle (Lee and Altintas, 1996; Malekian et al., 2009; Xu et al., 2015)....
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...In the present work, uncut chip thickness (me in Figure 2b) at any instant is obtained using the relation proposed for macro-ball end milling (Lee and Altintas, 1996; Armarego et al., 2002)....
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Journal Article•DOI•

Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining

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Z.J. Yuan¹, Ming Zhou¹, Shuliang Dong¹•Institutions (1)

Harbin Institute of Technology¹

01 Dec 1996-Journal of Materials Processing Technology

TL;DR: In this article, the relationship between the cutting edge radius and the minimum cutting thickness was analyzed, and the effect of cutting edge sharpness on the machined surface integrity was investigated.

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331 citations

"Development and experimental valida..." refers background or methods in this paper

...Yuan et al. (1996) reported that the critical value of uncut chip thickness for steel workpiece and high-speed steel or carbide tool falls between 0.2 and 0.4 times of cutting edge radius value....
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...…and cutting edge radius has been derived theoretically or based on experimental studies (Abdelmoneim and Scrutton, 1974; Basuray et al., 1977; Yuan et al., 1996; Liu et al., 2005; Liu andMelkote, 2007; Woon et al., 2008; Bissacco et al., 2008;Malekian et al., 2012; Rao and Shunmugam, 2012;…...
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...The value of limiting chip thickness in micro-cutting can be found analytically (Basuray et al., 1977) or using the value of uncut chip thickness to edge radius ratio (Yuan et al., 1996) from literature....
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..., 1977) or using the value of uncut chip thickness to edge radius ratio (Yuan et al., 1996) from literature....
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...Relation between the minimum uncut chip thickness and cutting edge radius has been derived theoretically or based on experimental studies (Abdelmoneim and Scrutton, 1974; Basuray et al., 1977; Yuan et al., 1996; Liu et al., 2005; Liu andMelkote, 2007; Woon et al., 2008; Bissacco et al., 2008;Malekian et al., 2012; Rao and Shunmugam, 2012; Srinivasa and Shunmugam, 2013)....
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Journal Article•DOI•

Size effect and tool geometry in micromilling of tool steel

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Ampara Aramcharoen¹, Paul Mativenga¹•Institutions (1)

University of Manchester¹

01 Oct 2009-Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology

TL;DR: In this paper, the size effect in micromilling hardened tool steel was observed by studying the effect of the ratio of undeformed chip thickness to the cutting edge radius on process performance, and how this ratio drove the specific cutting force, surface finish and burr formation in micro-scale machining.

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Abstract: The market for freeform and high quality microdies and moulds made of steel is predicted to experience a phenomenal growth in line with the demand for microsystems. However, micromachining of hardened steel is a challenge due to unpredictable tool life and likely differences in process mechanism compared to macro-scale machining. This paper presents an investigation of the size effect in micromilling of H13 hardened tool steel. In this case, the size effect in micromilling hardened tool steel was observed by studying the effect of the ratio of undeformed chip thickness to the cutting edge radius on process performance. The paper explores how this ratio drives the specific cutting force, surface finish and burr formation in micro-scale machining. In addition, the effect of different microend mill geometry on product quality was explored. The paper provides a valuable insight into optimum micro-scale machining conditions for obtaining the best surface finish and minimizing burr size.

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306 citations

"Development and experimental valida..." refers background in this paper

...The size effects are thus defined based on specific energy (Shaw, 2003; Subbiah and Melkote, 2006; Liu and Melkote, 2007; Aramcharoen and Mativenga, 2009; Piljek et al., 2014)....
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