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Floor surface roughness model considering tool vibration in the process of micro-milling

  • Xiaohong Lu
  • Haixing Zhang
  • Zhenyuan Jia
  • Yixuan Feng
  • Steven Y. Liang
ORIGINAL ARTICLE

Abstract

The high quality of the micro-machined surface is the basic for promoting micro-milling technology, so the understanding of surface forming mechanism and the relationship between micro-milling parameters and the surface roughness are important. In this paper, we establish a comprehensive floor surface model which predicts the surface roughness of the grooves under different cutting parameters and tool geometrical parameters in micro-milling. This model is based on the movement and vibration of micro-end mill and the forming of workpiece surface governed by elastic recovery and tool geometry. The kinematics of micro-milling operations directly affects the topography and is calculated by the trochoidal trajectory formula. The relative vibration of the tool to the workpiece, which affects the ultimate movement trajectory, is measured through experiments. Besides, the elastic recovery and the minimum cutting thickness included in the surface generation procedure are calculated based on the microscopic mechanics of strain gradient theory. Finally, experiments of slot micro-milling under different cutting parameters validate the accuracy of the surface prediction model.

Keywords

Surface roughness Tool vibration Elastic recovery Minimum cutting thickness Micro-milling Floor surface model 

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Notes

Funding information

The research is supported by the National Natural Science Foundation of China under Grant No. 51305061 and the State Foundation for Studying Abroad (CSC) under project number 201606055043. The financial contributions are gratefully acknowledged.

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Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  • Xiaohong Lu
    • 1
  • Haixing Zhang
    • 1
  • Zhenyuan Jia
    • 1
  • Yixuan Feng
    • 2
  • Steven Y. Liang
    • 2
  1. 1.School of Mechanical EngineeringDalian University of TechnologyDalianPeople’s Republic of China
  2. 2.The George W. Woodruff School of Mechanical EngineeringGeorgia Institute of TechnologyAtlantaUSA

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