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A New Mechanistic Approach for Micro End Milling Force Modeling

[+] Author Affiliations
Martin B. G. Jun, Chanseo Goo

University of Victoria, Victoria, BC, Canada

Mohammad Malekian, Simon S. Park

University of Calgary, Calgary, AB, Canada

Paper No. IMECE2010-38017, pp. 925-933; 9 pages
doi:10.1115/IMECE2010-38017
From:
  • ASME 2010 International Mechanical Engineering Congress and Exposition
  • Volume 3: Design and Manufacturing, Parts A and B
  • Vancouver, British Columbia, Canada, November 12–18, 2010
  • Conference Sponsors: ASME
  • ISBN: 978-0-7918-4427-4
  • Copyright © 2010 by ASME

abstract

This paper investigates the mechanistic modeling of micro end milling forces, with consideration of the effects of plowing, elastic recovery, effective rake angle, and flank face rubbing. Two different mechanistic models are developed for shearing- and plowing-dominant regimes. Micro end milling experiments are conducted to validate the model for Aluminum 6061; and, the model appropriately predicts force profiles for a wide range of feed rates, and prediction of the root mean square (RMS) values of the resultant forces is, on average, within a 12% error. The study of the model shows that plowing and rubbing force contributions are significant, especially at low feed rates. The edge radius is found to have a significant effect on plowing and rubbing force components and the effective rake angle, which indicates that it is important to maintain a low edge radius to reduce micro end milling forces.

Copyright © 2010 by ASME
Topics: Force , Modeling , Milling

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