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Modelling the cutting forces in micro-end-milling using a hybrid approach

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Abstract

This paper presents the development of a cutting force model for the micro-end-milling processes under various cutting conditions using a hybrid approach. Firstly, a finite element (FE) model of orthogonal micro-cutting with a round cutting edge is developed for medium-carbon steel. A number of finite element analyses (FEA) are performed at different uncut chip thicknesses and velocities. Based on the FEA results, the cutting force coefficients are extracted through a nonlinear algorithm to establish a relationship with the uncut chip thickness and cutting speed. Then, the cutting force coefficients are integrated into a mechanistic cutting force model, which can predict cutting forces under different cutting conditions. In order to account for the cutting edge effect, an effective rake angle is employed for the determination of the cutting force. A comparison of the prediction and experimental measured cutting forces has shown that the developed method provides accurate results.

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Authors and Affiliations

  1. Key Laboratory of Advanced Ceramics and Machine Technology of Ministry of Education, TianJin University, Tianjin, 300072, China

    Xiubing Jing & Yanling Tian

  2. Griffith School of Engineering, Griffith University (Gold Coast Campus), Parklands Drive Southport, Queensland, 4214, Australia

    Huaizhong Li

  3. School of Mechanical and Manufacturing Engineering, The University of New South Wales, Kensington, Australia

    Xiubing Jing & Jun Wang

Authors
  1. Xiubing Jing
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  2. Huaizhong Li
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  3. Jun Wang
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  4. Yanling Tian
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Correspondence to Huaizhong Li.

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Jing, X., Li, H., Wang, J. et al. Modelling the cutting forces in micro-end-milling using a hybrid approach. Int J Adv Manuf Technol 73, 1647–1656 (2014). https://doi.org/10.1007/s00170-014-5953-x

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  • DOI: https://doi.org/10.1007/s00170-014-5953-x

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