Effect of circular tool path on cutting force profile in micro-end-milling

  1. Get@NRC: Effect of circular tool path on cutting force profile in micro-end-milling (Opens in a new window)
DOIResolve DOI: http://doi.org/10.1177/0954406211423575
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Journal titleProceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science
Pages15891600; # of pages: 12
SubjectChip thickness; Cutting force measurements; Cutting force signals; Cutting forces; End-milling; Feed-rates; Material removal; Micro milling; Micro-end-milling; Rotation angles; Rotational speed; Toolpaths; Cutting; Micromachining; Milling (machining); Signal processing; Scanning
AbstractMicro-end-milling requires high spindle rotational speed to achieve effective material removal. This results in the requirement of tool stoppage or slowdown during a micro-end-milling operation, a deterrent to productivity and to part acceptability. A circular tool path geometry can avoid discontinuities in the tool movements leading to a more consistent and smooth material removal. However, optimal process planning for such a tool path will require detailed understanding of the chip-formation mechanism in circular end-milling. The cut geometry during end-milling along a circular tool path is often approximated as that of a linear tool path. Although this assumption works well for circular tool paths with higher tool path radius, this is not the case for lower tool path radius often used in micro-milling. In this study, the effect of circular tool path on the cutting force for varying tool path rotation angle, tool path radius, and feed rate is experimentally investigated. Systematic signal processing was applied to analyse the measured cutting force signal along linear and several circular tool paths. Qualitative as well as quantitative differences were observed in the cutting force profiles obtained using different tool path radii, tool path orientations, and feed rates. This implies the need for an improved chip thickness formulation dedicated to micro-end-milling with circular tool path rather than approximating it with formulations derived for linear tool path. © Authors 2011.
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AffiliationNational Research Council Canada (NRC-CNRC); Automotive (AUTO-AUTO)
Peer reviewedYes
NPARC number21269179
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Record identifierd8a395e9-52b5-4682-ae0b-e04ecb1c96e4
Record created2013-12-12
Record modified2016-05-09
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