Modelling And Analysis Of Micro-End Milling Force

With the increasing need for microminiaturization product and the development of the technology, Micro milling technology plays an important role in complicated 3D micro parts manufacturing. Comparable with conventional milling, feed engagement in micro-milling is limited in several micrometers or even lower due to the weak rigidity of micro-milling tool.Then as a result of friction, pressing or grooving of the work-piece from tool edge, the elastic-plastic deformation aggravates. So it is necessary to study the mechanism of micro-milling deeper.In the paper, towards the characters different from conventional milling, the model of micro-milling force is performed using analytic method based on the theory of metal cutting and elastic-plastic mechanics. Finally, empirical equation of micro-milling forces is built through experiment to achieve the object of predicting the micro-milling forces precisely.First of all, the difference between micro end milling and macro end milling is developed. through experiment. The paper incorporates the minimum chip thickness computation algorithm the elastic spring back in order to predict the effects of the plough force on cutting force.Secondly, orthogonal cutting force of micro element is established, and formation mechanism of cutting zone, forces that the tool suffered, friction characteristic of cutter/workpiece area, and shear angle is analyzed. According to the characteristic of orthogonal cutting force the micro end milling force model was established. Experiments are adopted to validate the cutting force model.Finally, an orthogonal experiment scheme is adopted in order to investigate cutting forces. Brass are used in the experiment with hard alloy flat end milling cutter. The dynamic cutting force curves are obtained. A prediction model of cutting force is built and the significance test is finished.