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Analytical modelling and experimental validation of micro-ball-end milling forces with progressive tool flank wear

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Abstract

In this paper, an analytical model for estimating the micro-ball-end milling forces is presented based on experimental investigation of progressive tool flank wear. The wear form and wear mechanism of the micro-ball-end mill are revealed through a series of micro-ball-end milling experiments. The effecting laws of cutting parameters such as feed per tooth, cutting speed, and inclined angle on tool flank wear are investigated. The experimental results indicate that the progressive tool flank wear has significant influence on cutting force in micro-milling of NAK80 steel. To assure the prediction accuracy of micro-ball-end milling force, an analytical methodology is presented to estimate cutting forces which considers not only the shearing force resulted from chip formation but also ploughing and rubbing force resulted by combined elastic contact and plastic flow at enlarged flank wear land. To verify the validity of the developed analytical model, a series of experiments are carried out on high-precision machine by using micro-ball-end mill with different flank wear lands. The comparisons of theoretical and experimental cutting forces indicate that the developed model can provide acceptable predicted accuracy. The proposed analytical cutting force model could be employed to monitor progressive tool flank wear land width in micro-ball-end milling of complex surface in future work.

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Abbreviations

α, αe :

Nominal/ effective rake angle

α t :

Empirical constant

β :

Friction angle

ε,\( \dot{\varepsilon} \),\( {\dot{\varepsilon}}_0 \) :

Equivalent strain, strain rate, reference strain rate

ς :

Ratio of lc to tc

δ :

Surface inclination angle

R0, η0, γ0, α0, and ρ0 :

Slip-line parameters

κ :

Axial position angle

η c :

Chip velocity angle

θ k :

Position angle of cutting edge element

θ s :

Material separation angle

σ JC :

Reference yield stress

σw, σ0 :

Normal stress

τw, τ0, τ :

Shear stress

μ :

Friction coefficient

ξ :

Exponential constant of tool-chip interface pressure distribution

ρ :

Material density

ϕ :

Shear angle

A, B, C, m, n :

Johnson-Cook model parameters

b :

Burgers vector

db :

Projected length of cutting edge element along cutting velocity

ds :

Length of the curved cutting edge element

f t :

Feed per tooth

Fx, Fy :

Cutting forces in x and y direction

G :

Shear modulus

h c :

Undeformed chip thickness

i :

Oblique angle

Ktc, Krc, Kac :

Shear-specific coefficients

Kte, Kre, Kae :

Ploughing-specific coefficients

Ktw, Krw, Kaw :

Friction-specific coefficients

M :

Taylor factor

r e :

Cutting edge radius

\( \overline{r} \) :

Nye factor

T0, Tm, Ts :

Temperatures of room, melt, and primary shear plane

VB, VB*:

Flank wear land width, critical flank wear land width

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Funding

This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 51805191, 51625502) and the National Key Research and Development Program of China (Grant Nos. 2018YFB1701904).

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Authors and Affiliations

  1. National NC System Engineering Research Center, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Lin Zhou, Ben Deng, Rong Yan,  MinghuiYang & Hao Sun

  2. State Key Laboratory of Digital Manufacturing Equipment and Technology, School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, 430074, China

    Fangyu Peng

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  1. Lin Zhou
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  2. Ben Deng
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  4. Rong Yan
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Correspondence to Fangyu Peng.

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Zhou, L., Deng, B., Peng, F. et al. Analytical modelling and experimental validation of micro-ball-end milling forces with progressive tool flank wear. Int J Adv Manuf Technol 108, 3335–3349 (2020). https://doi.org/10.1007/s00170-020-05574-6

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