Modeling of cutting forces in micro milling including run-out
Author
Kanlı, Muammer
Advisor
Karpat, Yiğit
Date
2014Publisher
Bilkent University
Language
English
Type
ThesisItem Usage Stats
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Abstract
Micro milling is widely used in precision manufacturing industry which is
suitable for producing micro scale parts having three dimensional surfaces made
from engineering materials. High material removal rate is its main advantage
over other micro manufacturing technologies such as lithography, micro EDM,
laser ablation etc. Modeling of micro milling process is essential to maximize
material removal rate and to obtain desired surface quality at the end of the
process.
The first step in predicting the performance of micro milling process is an
accurate model for machining forces. Machining forces are directly related to
machine tool characteristics where the process is performed. The spindle and the
micro milling tool affects the machining forces. In this thesis, the influence of
runout of the spindle system on micro milling forces is investigated. Two different
spindle systems with different levels of runout are considered and necessary
modifications are introduced to model the trajectory of the tool center for better
prediction of process outputs in the presence of runout. A modified mechanistic
force modeling technique has been used to model meso/micro scale milling forces.
Detailed micro milling experiments have been performed to calculate the cutting
and edge force coefficients for micro end mills having diameters of 2, 0.6, and 0.4
mm while machining titanium alloy Ti6AL4V. Good agreements have been
observed between the predicted and measured forces. It is found that statically
measured runout values do not translate into dynamic machining conditions due
to machining forces acting on the end mill.