New Mathematic Method of Calculating Instantaneous Un-deformed Chip Thickness with Tool Run-out in Micro-end-milling

doi:10.3901/JME.2016.03.169

Abstract

Abstract: A new mathematic method of calculating instantaneous un-deformed chip thickness is established through analysis of true cutting tool tip trajectories. Two specific formulas are given in condition of two-flute and four-flute micro end milling. Then cutting process of each tooth with tool run out is analyzed by applying the new method in two-flute and four-flute micro slot milling. This new method considered comprehensive radial cutter run-out which include the spindle run-out and assemble errors and can be used to calculate the un-deformed chip thickness of cutting tools with any number of teeth. The accuracy and practicability are verified and some differences between micro milling and traditional milling process are pointed out by comparing the new method with other methods such as Bao’s and Newton-Raphson method. Cutting force is predicted based on the new method in micro slot milling experiment. The simulation result shows a very good agreement with experiment data.

Key words: cutting mechanics, micro-milling, run-out, tool trochoidal trajectory, un-deformed chip thickness

CLC Number:

TG161

NIE Qiang, HUANG Kai, BI Qingzhen, ZHU Limin. New Mathematic Method of Calculating Instantaneous Un-deformed Chip Thickness with Tool Run-out in Micro-end-milling[J]. Journal of Mechanical Engineering, 2016, 52(3): 169-178.

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