The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics

Abstract

In the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual trochoidal trajectories of the cutting edge on micro-milling forces should also be considered comprehensively. In this paper, the tool runout error in the micro-milling process is first analysed, and an instantaneous undeformed chip thickness model is established considering the runout error. On this basis, the dynamic deformation of the micro-cutting tool and thin-walled micro-part is studied, and an instantaneous, undeformed, chip-thickness model is proposed with the consideration of both the runout error and dynamic deformation. The dynamic parameters of the machining system are obtained using the receptance coupling method. Finally, thin-walled micro-part machining experiments are carried out, and the obtained results of micro-milling force simulation based on the proposed model are compared with the experimental results. The results indicate that the micro-milling force modelling, by taking the influence of machining dynamics into account, has better prediction accuracy, and the difference between the predicted resultant forces and the experimental results is less than 11%.

Keywords

• thin-walled micro-parts
• micro-milling
• cutting force model
• machining dynamics
• cutting tool runout