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Prediction of micro milling force and surface roughness considering size-dependent vibration of micro-end mill

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Abstract

When the characteristic structure size of the component is at the micron level, the internal crystal grains, grain boundaries, and pore defects of the component material with the same size at the micron level cannot be ignored, so the micro-sized component will show different physical properties from the macro-sized component, which is called size effect. Since the tool diameter of a micro-end mill is in the micron level, the micro-end mill will also show a significant size effect phenomenon. In addition, in the micro milling process, because the surface roughness that affects the performance and service life of micro parts is mainly influenced by the vibration of the micro-end mill, in order to enhance the machined surface quality, it is crucial to research the formation mechanism of surface topography in the micro milling process. In this paper, a comprehensive method is proposed to predict micro-end mill vibration, micro milling force, and surface roughness. At first, a size-dependent dynamic model of micro-end mill is presented based on the strain gradient elasticity theory (SGET). Secondly, considering the feedback of a micro-end mill vibration, the micro milling force model is presented and solved through the iterative method. Then the machined surface topography is simulated through the actual cutting edge trajectory considering the micro-end mill size-dependent vibration and material elastic recovery. The results show that the vibration of the micro-end mill will increase the micro milling force and surface roughness. In order to verify the accuracy and efficiency of the presented method, experiments are performed, and it is found that the predicted results are consistent with the experimental results.

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All data generated or analyzed during this study are included in this published article.

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Funding

This work was supported by the National Natural Science Foundation of China (grant numbers 51875320, 51922066) and the Natural Science Outstanding Youth Fund of Shandong Province (grant number ZR2019JQ19). This work was also supported by grants from Taishan Scholar Foundation (grant number TS20130922).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan, People’s Republic of China

    Yicong Du, Qinghua Song & Zhanqiang Liu

  2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, People’s Republic of China

    Qinghua Song & Zhanqiang Liu

Authors
  1. Yicong Du
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  2. Qinghua Song
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  3. Zhanqiang Liu
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Contributions

Yicong Du and Qinghau Song contributed the central idea, analyzed most of the data, and wrote the initial draft of the paper. The remaining authors contributed to refining the ideas, carrying out additional analyses, and finalizing this paper.

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Correspondence to Qinghua Song.

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Du, Y., Song, Q. & Liu, Z. Prediction of micro milling force and surface roughness considering size-dependent vibration of micro-end mill. Int J Adv Manuf Technol 119, 5807–5820 (2022). https://doi.org/10.1007/s00170-021-08535-9

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  • DOI: https://doi.org/10.1007/s00170-021-08535-9

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