Skip to main content
SpringerLink
Log in

An evaluation of micro milling chip thickness models for the process mechanics

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

An accuracy of the chip thickness models used in the micro milling mechanics models directly affects the accuracy of the cutting force predictions. There are different chip thickness models derived from various kinematic analyses for the micro milling in the literature. This article presents an evaluation of chip thickness models for micro milling by examining their direct effects on predictions of cutting forces. Performances of four chip thickness models for micro milling existing in the literature are tested and compared with the experimental force measurements. Micro end milling experiments were conducted on an aerospace-grade aluminum alloy Al7050 for different feed rate values. The root mean square deviation and the coefficient of determination values between the estimated and measured micro milling forces are presented for the comparative evaluation of the major chip thickness models at various feed per tooth to tool diameter ratios.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Dornfeld D, Min S, Takeuchi Y (2006) Recent advances in mechanical micromachining. CIRP Ann Manuf Technol 55:745–768

    Article  Google Scholar 

  2. Wan M, Murat Kilic Z, Altintas Y (2014) Mechanics and dynamics of multifunctional tools. J Manuf Sci Eng 137:11–19

    Google Scholar 

  3. Wan M, Altintas Y (2014) Mechanics and dynamics of thread milling process. Int J Mach Tools Manuf 87:16–26

    Article  Google Scholar 

  4. Armarego EJA, Deshpande NP (1991) Computerized end-milling force predictions with cutting models allowing for eccentricity and cutter deflections. CIRP Ann Manuf Technol 40:25–29

    Article  Google Scholar 

  5. Leu MC, Lu F, Blackmore D (1998) Simulation of NC machining with cutter deflection by modelling deformed swept volumes. CIRP Ann Manuf Technol 47:441–446

    Article  Google Scholar 

  6. Mamedov A, Layegh KSE, Lazoglu I (2015) Instantaneous tool deflection model for micro milling, Int J of Adv Manuf Technol, 79: 769-777

  7. Altintas Y, Stepan G, Merdol D, Dombovari Z (2008) Chatter stability of milling in frequency and discrete time domain. CIRP J Manuf Sci Technol 1:35–44

    Article  Google Scholar 

  8. Budak E, Tunç LT, Alan S, Özgüven HN (2012) Prediction of workpiece dynamics and its effects on chatter stability in milling. CIRP Ann Manuf Technol 61:339–342

    Article  Google Scholar 

  9. Park SS, Rahnama R (2010) Robust chatter stability in micro-milling operations. CIRP Ann Manuf Technol 59:391–394

    Article  Google Scholar 

  10. Jawahir IS, Brinksmeier E, M’Saoubi R, Aspinwall DK, Outeiro JC, Meyer D, Umbrello D, Jayal AD (2011) Surface integrity in material removal processes: recent advances. CIRP Ann Manuf Technol 60:603–626

    Article  Google Scholar 

  11. Lazoglu I, Ulutan D, Alaca BE, Engin S, Kaftanoglu B (2008) An enhanced analytical model for residual stress prediction in machining. CIRP Ann Manuf Technol 57:81–84

    Article  Google Scholar 

  12. Kersting P, Biermann D (2014) Modeling techniques for simulating workpiece deflections in NC milling. CIRP J Manuf Sci Technol 7:48–54

    Article  Google Scholar 

  13. Denkena B, Böß V, Nespor D, Samp A (2011) Kinematic and stochastic surface topography of machined TiAl6V4-parts by means of ball nose end milling. Procedia Eng 19:81–87

    Article  Google Scholar 

  14. Jin X, Altintas Y (2012) Prediction of micro-milling forces with finite element method. J Mater Process Technol 212:542–552

    Article  Google Scholar 

  15. Park SS, Malekian M (2009) Mechanistic modeling and accurate measurement of micro end milling forces. CIRP Ann Manuf Technol 58:49–52

    Article  Google Scholar 

  16. Malekian M, Park SS, Jun MBG (2009) Modeling of dynamic micro-milling cutting forces. Int J Mach Tools Manuf 49:586–598

    Article  Google Scholar 

  17. Wang J, Zheng CM (2002) An analytical force model with shearing and ploughing mechanisms for end milling. Int J Mach Tools Manuf 42:761–771

    Article  Google Scholar 

  18. Lucca D, Seo Y, Komanduri R (1993) Effect of tool edge geometry on energy dissipation in ultraprecision machining. CIRP Ann Manuf Technol 42:83–86

    Article  Google Scholar 

  19. Martellotti M (1941) An analysis of milling process. ASME J Manuf Sci Eng 63:677–700

    Google Scholar 

  20. Bao W (2000) Modeling micro-end-milling operations. Part I: analytical cutting force model. Int J Mach Tools Manuf 40:2155–2173

    Article  Google Scholar 

  21. Bao WY, Tansel IN (2000) Modeling micro end milling operations . Part II : tool run-out. Int J Mach Tools Manuf 40:2175–2192

    Article  Google Scholar 

  22. Li HZ, Liu K, Li XP (2001) A new method for determining the undeformed chip thickness in milling. J Mater Process Technol 113:378–384

    Article  Google Scholar 

  23. Li XP, Li HZ (2004) Theoretical modelling of cutting forces in helical end milling with cutter runout. Int J Mech Sci 46:1399–1414

    Article  MATH  Google Scholar 

  24. Kang YH, Zheng CM (2013) Mathematical modelling of chip thickness in micro-end- milling: a Fourier modelling. Appl Math Model 37:4208–4223

    Article  Google Scholar 

  25. Wang ZG, Rahman M, Wong YS, Neo KS, Sun J (2016) Geometrical Modeling for Micro End Milling Process, Proceeding of the First International Conference on Precision Engineering and Micro/Nano Technology in Asia 131–5

  26. Altintas Y (2012) Manufacturing automation, metal cutting mechanics, machine tool vibrations and CNC design, 2nd edn. Cambridge University Press

Download references

Author information

Authors and Affiliations

  1. Manufacturing and Automation Research Center, Mechanical Engineering Department, Koc University, Sariyer, Istanbul, 34450, Turkey

    Ali Mamedov & Ismail Lazoglu

Authors
  1. Ali Mamedov
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ismail Lazoglu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Ismail Lazoglu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mamedov, A., Lazoglu, I. An evaluation of micro milling chip thickness models for the process mechanics. Int J Adv Manuf Technol 87, 1843–1849 (2016). https://doi.org/10.1007/s00170-016-8584-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8584-6

Keywords

Search

Navigation