0
Research Papers

Micro Flat End Milling Simulation Model With Instantaneous Plowing Area Prediction

[+] Author and Article Information
Abdolreza Bayesteh

Thermo Fisher Scientific,
5250 Mainway,
Burlington, ON L7L 5Z1, Canada
e-mail: reza.bayesteh@thermofisher.com

Junghyuk Ko

Department of Mechanical Engineering,
University of Victoria,
PO Box 1700 STN CSC,
Victoria, BC V8W 2Y2, Canada
e-mail: jko@engr.uvic.ca

Martin Byung-Guk Jun

Mem. ASME
Department of Mechanical Engineering,
University of Victoria,
PO Box 1700 STN CSC,
Victoria, BC V8W 2Y2, Canada
e-mail: mbgjun@uvic.ca

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received October 14, 2015; final manuscript received February 6, 2016; published online March 23, 2016. Assoc. Editor: Sangkee Min.

J. Micro Nano-Manuf 4(2), 021004 (Mar 23, 2016) (6 pages) Paper No: JMNM-15-1072; doi: 10.1115/1.4032757 History: Received October 14, 2015; Revised February 06, 2016

There is an increasing demand for product miniaturization and parts with features as low as few microns. Micromilling is one of the promising methods to fabricate miniature parts in a wide range of sectors including biomedical, electronic, and aerospace. Due to the large edge radius relative to uncut chip thickness, plowing is a dominant cutting mechanism in micromilling for low feed rates and has adverse effects on the surface quality, and thus, for a given tool path, it is important to be able to predict the amount of plowing. This paper presents a new method to calculate plowing volume for a given tool path in micromilling. For an incremental feed rate movement of a micro end mill along a given tool path, the uncut chip thickness at a given feed rate is determined, and based on the minimum chip thickness value compared to the uncut chip thickness, the areas of plowing and shearing are calculated. The workpiece is represented by a dual-Dexel model, and the simulation properties are initialized with real cutting parameters. During real-time simulation, the plowed volume is calculated using the algorithm developed. The simulated chip area results are qualitatively compared with measured resultant forces for verification of the model and using the model, effects of cutting conditions such as feed rate, edge radius, and radial depth of cut on the amount of shearing and plowing are investigated.

Copyright © 2016 by ASME
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Fig. 1

Workpiece represented with Dexels

Grahic Jump Location
Fig. 2

G-code tool path conversion to arrays of points and segments

Grahic Jump Location
Fig. 3

Dexel trimming at the intersection points

Grahic Jump Location
Fig. 4

Dexel trimming and creation of arrays of removed and added points

Grahic Jump Location
Fig. 5

Chip load created from intersection points

Grahic Jump Location
Fig. 6

Minimum chip thickness and intersection lines for plowing area calculation

Grahic Jump Location
Fig. 7

Plowing area calculation when uncut chip thickness is less than the minimum chip thickness

Grahic Jump Location
Fig. 8

Plowing area calculation when cutter is not fully immersed

Grahic Jump Location
Fig. 9

Plowing area calculation when cutter is partially outside workpiece

Grahic Jump Location
Fig. 10

Micro flat end milling simulation software interface

Grahic Jump Location
Fig. 11

Experimental setup for micromilling operations

Grahic Jump Location
Fig. 12

(a) Pocket machined for experiment, (b) tool path for the pocket, and (c) a photograph of the machined pocket

Grahic Jump Location
Fig. 13

Simulation and experiment results at the feed rate of 0.25 μm/tooth

Grahic Jump Location
Fig. 14

Simulation and experiment results at the feed rate of 0.375 μm/tooth

Grahic Jump Location
Fig. 15

Simulation and experiment results at the feed rate of 0.5 μm/tooth

Grahic Jump Location
Fig. 16

Simulation and experiment results at the feed rate of 0.625 μm/tooth

Grahic Jump Location
Fig. 17

Results of simulations to study the effect of feed rate

Grahic Jump Location
Fig. 18

Results of simulations to study the effect of edge radius and radial depth of cut

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In