A mechanistic model of cutting forces in micro-end-milling with cutting-condition-independent cutting force coefficients

Han Ul Lee, Dong Woo Cho*, Kornel F. Ehmann

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

47 Scopus citations

Abstract

Complex three-dimensional miniature components are needed in a wide range of industrial applications from aerospace to biomedicine. Such products can be effectively produced by micro-end-milling processes that are capable of accurately producing high aspect ratio features and parts. This paper presents a mechanistic cutting force model for the precise prediction of the cutting forces in micro-end-milling under various cutting conditions. In order to account for the actual physical phenomena at the edge of the tool, the components of the cutting force vector are determined based on the newly introduced concept of the partial effective rake angle. The proposed model also uses instantaneous cutting force coefficients that are independent of the end-milling cutting conditions. These cutting force coefficients, determined from measured cutting forces, reflect the influence of the majority of cutting mechanisms involved in micro-end-milling including the minimum chip-thickness effect. The comparison of the predicted and measured cutting forces has shown that the proposed method provides very accurate results.

Original languageEnglish (US)
Pages (from-to)311021-311029
Number of pages9
JournalJournal of Manufacturing Science and Engineering, Transactions of the ASME
Volume130
Issue number3
DOIs
StatePublished - Jun 1 2008

Keywords

  • Cutting force model
  • Cutting-condition-independent cutting force coefficients
  • Micro-end-milling
  • Uncut chip thickness

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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