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Theoretical study on the effects of the axial and radial runout and tool corner radius on surface roughness in slot micromilling process

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Abstract

This paper presented a theoretical study on the effects of the axial and radial runout and tool corner radius on surface roughness in the slot micromilling process. Firstly, the actual feed rate was calculated based on the optimized model for the uncut chip thickness. Then, the milled morphologies in five typical cases are analyzed, and the details of the flowchart for the modeling process are drawn, and the corresponding surface morphology and surface roughness are presented. Next, the effects of radial runout offset and angle, axial offset, and tool corner radius on surface roughness were studied. Furthermore, three typical surface morphologies, i.e., a single cutting phenomenon, unbalanced cutting phenomena due to the radial runout and axial runout, were obtained from the slot micromilling experiment, which could verify the validity of the model indirectly. In the end, the approaches for improving the predicting accuracy were discussed. The findings could provide a better understanding of the surface formation process during slot micromilling process.

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Abbreviations

R 1 :

The rotational radius of tooth 1 (μm)

R 2 :

The rotational radius of tooth 2 (μm)

R :

The nominal radius of the milling tool (μm)

r 0 :

The radial runout offset (μm)

λ:

The radial runout angle

K :

The number of the flutes

k :

The flute number

n :

The spindle velocity (rev/min)

f t :

The feed rate (μm/z)

t :

Time (s)

h 1 :

Uncut chip thickness of the Nie’s model (μm)

h 2 :

Uncut chip thickness of the Bao’s model (μm)

h 3 :

Uncut chip thickness of the Wan’s model (μm)

φ i :

Cutter rotation angle (rad)

m :

The current tooth i is removing the material left by the mth previous tooth

Ri,j(z):

Actual cutting radii of the jth axial disk element of the ith flute at z (μm)

h a :

Actual feed rate (μm/z)

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Acknowledgments

The authors are also grateful to the colleagues for their essential contribution to the work.

Funding

This work is supported by the China Postdoctoral Science Foundation (Grant Nos. 2019M663043), the National Natural Science Foundation of China (Grant Nos. 51575360 and 51805333), and the Science and Technology Innovation Commission Shenzhen (Grant Nos. JCYJ20170817094310049 and JSGG20170824111725200).

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Authors and Affiliations

  1. Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave. 3688, Shenzhen, 518060, Guangdong, China

    Tao Wang, Xiaoyu Wu, Guoqing Zhang, Bin Xu & Yinghua Chen

  2. Key Laboratory of Optoelectronic Devices and Systems of Ministry of Education and Guangdong Province, College of Optoelectronic Engineering, Shenzhen University, Shenzhen, 518060, China

    Tao Wang & Shuangchen Ruan

Authors
  1. Tao Wang
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  2. Xiaoyu Wu
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  3. Guoqing Zhang
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  4. Bin Xu
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Correspondence to Xiaoyu Wu.

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Wang, T., Wu, X., Zhang, G. et al. Theoretical study on the effects of the axial and radial runout and tool corner radius on surface roughness in slot micromilling process. Int J Adv Manuf Technol 108, 1931–1944 (2020). https://doi.org/10.1007/s00170-020-05492-7

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  • DOI: https://doi.org/10.1007/s00170-020-05492-7

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