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Numerical simulation of micro-element cutting and milling force prediction in micro ball-end milling

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Abstract

In order to better analyze and control the micro milling process of micro ball-end milling cutter, a method combining finite element method (FEM) and regression analysis is proposed to simulate and analyze the micro cutting process of cutting edge micro-element at different axial height positions to achieve micro milling force prediction. Combining cutting edge curve equations and actual measurements establish an accurate micro ball-end milling cutter model, and discrete along the axial direction of the cutter to obtain multiple sets of cutting edge micro-element of equal thickness. In this study, a workpiece micro-element model corresponding to the axial height position of the cutting edge micro-element is established based on the actual cycloidal motion trajectory during the micro milling of the cutting edge. Finite element simulation of single-edge bevel cutting of cutting micro-elements is implemented. Based on the micro cutting force data obtained from the micro cutting simulation, regression analysis is used to obtain the cutting edge micro-element unit cutting force related to axial height and cutter rotation angle for a certain amount of feed per tooth, and then the integral summation is used to achieve the micro milling force prediction. A comparative analysis of the full slot micro milling experiments shows that the predicted micro milling forces are in good agreement with the measured values, which directly verifies the correctness and reliability of the cutting edge micro-element cutting numerical simulation and micro milling force prediction method in the paper.

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Funding

The research presented in this document was supported by the Scientific Research Project of Tianjin Municipal Education Commission (2020KJ015).

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Authors and Affiliations

  1. College of Aeronautical Engineering, Civil Aviation University of China, Tianjin, 300300, China

    Yigang Sun, Shenghui Hou, Baichun Li, Hao Yu, Xiaokun Li, Yong Liu & Zhenpeng He

  2. Tianjin Bu Er Technology Co., Ltd, Tianjin, 300300, China

    Fangchao Yan

Authors
  1. Yigang Sun
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  2. Shenghui Hou
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  3. Baichun Li
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  4. Hao Yu
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  5. Xiaokun Li
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  6. Yong Liu
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  7. Zhenpeng He
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  8. Fangchao Yan
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Contributions

Yigang Sun and Baichun Li contributed to the conception and design of this study. Shenghui Hou, Hao Yu, and Xiaokun Li were involved in the finite element modeling and simulation result analysis. Yong Liu, Zhenpeng He, and Fangchao Yan collected experimental data and provided suggestions on the content of the paper. The first draft of this article was written by Yigang Sun and Shenghui Hou. And the remaining authors were involved in the revision of the paper. The final manuscript was read and approved by all authors.

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Correspondence to Baichun Li.

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Sun, Y., Hou, S., Li, B. et al. Numerical simulation of micro-element cutting and milling force prediction in micro ball-end milling. Int J Adv Manuf Technol 125, 2305–2322 (2023). https://doi.org/10.1007/s00170-023-10839-x

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