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Micro-milling force modeling with tool wear and runout effect by spatial analytic geometry

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Abstract

One of the major limitations of micro-milling applications in industries is its fast tool wear, which leads to low machining precision and efficiency. An accurate force model is fundamental for optimization micro-milling processes and minimize the tool wear. However, a generic model with tool runout and wear effect has not yet been established, which limits its practical application under varied working conditions. In this paper, a new idea is introduced by applying the spatial analytic geometry (SAG) method, under this framework the micro-milling force model is established based on the analysis of the geometrical relationship among the cutting edge positions, pre-processed workpiece morphology, and cutting force directions considering tool runout and wear effect. In this model, the tool runout is identified exclusively by only one parameter, namely the distance away from the center that perpendicular to the feed direction, so that it could be calibrated conveniently by calculating the ratio of resultant forces corresponding to different cutting edges. The tool wear–induced force is then modeled as increment of force coefficients to the original model. Therefore, the new force model with considering tool wear has the same form as the fresh tool. Finally, the accuracy and efficiency of the model are validated by experiments under varied working conditions.

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Abbreviations

SA:

Spatial analytic geometry

UCT:

Uncut chip thickness

XwYwZw-Ow :

Workpiece coordinates

XTYTZT-OT :

Tool coordinates

XSYSZS-OS :

Spindle coordinates

dFr, Fr :

Radial force

dFt, Ft :

Tangential force

φ :

Rotation angle of the tool

Ktc, Krc :

Coefficients of tangential and radial force

dh j :

UCT of the discrete element

db :

Length of the discrete element along the tool edge

Nj :

Amount of the discrete element

r1, r2 :

Rotating radius around the ZS-axis for the two edges

r out :

Tool runout

xout, yout :

Tool axis position parameters

θ out :

Angle between YS-axis and linkage of tool edge and center

r t :

Tool radius

f t :

Feed per tooth

rts1, rts2 :

Rotation radiuses of the two edges

\( {K}_{\mathbf{tc}}^{\mathbf{wear}} \), \( {K}_{\mathbf{rc}}^{\mathbf{wear}} \) :

Coefficients of tangential and radial force considering tool wear

P :

Tool lead

N :

Number of edges

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Funding

This project is supported by the Natural Science Foundation of Jiangsu Province of China (No. BK20160563) and the National Natural Science Foundation of China (No. 51605207).

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Authors and Affiliations

  1. School of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang, 212003, China

    Guochao Li

  2. Institute of Advanced Manufacturing Technology Hefei Institutes of Physical Science, Chinese Academy of Science, Huihong Building, Changwu Middle Road 801, Changzhou, 213164, Jiangsu, China

    Guochao Li, Si Li & Kunpeng Zhu

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  1. Guochao Li
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Correspondence to Guochao Li or Kunpeng Zhu.

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Li, G., Li, S. & Zhu, K. Micro-milling force modeling with tool wear and runout effect by spatial analytic geometry. Int J Adv Manuf Technol 107, 631–643 (2020). https://doi.org/10.1007/s00170-020-05008-3

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