This paper presents the prediction of cutting forces and chatter stability of micro-milling operations from the material's constitutive flow stress and structural dynamics of the micro-end mill. The cutting force coefficients are identified either using previously presented slip-line field or finite element methods by considering the effects of chip size, cutting edge radius, rake angle and cutting speed. The process damping caused by the plowing of round edge is modeled by finite element method. The frequency response function of the fragile micro-mill is measured through specially devised piezo actuator mechanism. Dynamic model of micro-milling with the velocity dependent process damping mechanism is presented, and the chatter stability is predicted in frequency domain. The proposed models have been experimentally verified in micro-milling of AISI 1045 steel.
Chatter Stability Model of Micro-Milling With Process Damping
Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 10, 2012; final manuscript received February 18, 2013; published online May 24, 2013. Assoc. Editor: Burak Ozdoganlar.
Jin, X., and Altintas, Y. (May 24, 2013). "Chatter Stability Model of Micro-Milling With Process Damping." ASME. J. Manuf. Sci. Eng. June 2013; 135(3): 031011. https://doi.org/10.1115/1.4024038
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