Simulation Study Of The Mechanical Properties And Geometry Of The Micro-cutter

Micro cutting is a rising advanced manufactured technology in recent years. It meets the demands of machining micro-part as well as green-manufacturing. Micro milling is a new technology in micro cutting field. With the development of ultra-precise manufactured technology, the investigation about micro milling has been deepened continuously. Micro milling tools is always an important study direction in micro milling. This paper investigates the machining mechanism, dynamic characteristics and geometry about micro tools.In micro milling, due to the tiny dimension, the cutting edge of micro tool can not be assumed absolutely as sharp any more. The rounded edge effect of cutting tool brings a series of special phenomena including negative rank angle, minimum cutting thickness and size-effect. Therefore, firstly, the deep analysis of the machining mechanism is given. Secondly, when the instantaneous cutting thickness is less than the minimum cutting thickness, no chip formation occurs and only ploughing/rubbing takes place. Taking the effects of ploughing, elastic recovery, run-out and dynamics into consideration, the mechanistic modeling of micro milling forces is stated. Thirdly, the dynamic characteristics of micro-milling tool are analyzed by using FEM with different extended lengths. Meanwhile, the inherent frequency and mode of vibration are studied. The stress and distortion characteristics are also discussed. Furthermore, various types of tool geometry, such as two-flute end mills, triangle-based(△-type) end mills, semi circle-based(D-type) end mills and single-edge end mills, are studied. The stability analyses of these tools are concluded by means of FEM simulations. Corresponding to the results of the simulation, the geometry of tools are compared in several steps. The triangle-based(△-type) end mills and single-edge end mills are better than two-flute end mills and semi circle-based(D-type) end mills in machining capability.