Micro milling is a flexible and economical method to fabricate micro components with three-dimensional geometry features over a wide range of engineering materials. But the surface roughness and micro topography always limit the performance of the machined micro components. This paper presents a surface generation simulation in micro end milling considering both axial and radial tool runout. Firstly, a surface generation model is established based on the geometry of micro milling cutter. Secondly, the influence of the runout in axial and radial directions on the surface generation are investigated and the surface roughness prediction is realized. It is found that the axial runout has a significant influence on the surface topography generation. Furthermore, the influence of axial runout on the surface micro topography was studied quantitatively, and a critical axial runout is given for variable feed per tooth to generate specific surface topography. Finally, the proposed model is validated by means of experiments and a good correlation is obtained. The proposed surface generation model offers a basis for designing and optimizing surface parameters of functional machined surfaces.
Wanqun Chen
,
Yazhou Sun
,
Dehong Huo
,
Xiangyu Teng
. Modelling of the Infuence of Tool Runout on Surface Generation in Micro Milling[J]. Chinese Journal of Mechanical Engineering, 2019
, 32(1)
: 2
-2
.
DOI: 10.1186/s10033-019-0318-x
Micro milling is a flexible and economical method to fabricate micro components with three-dimensional geometry features over a wide range of engineering materials. But the surface roughness and micro topography always limit the performance of the machined micro components. This paper presents a surface generation simulation in micro end milling considering both axial and radial tool runout. Firstly, a surface generation model is established based on the geometry of micro milling cutter. Secondly, the influence of the runout in axial and radial directions on the surface generation are investigated and the surface roughness prediction is realized. It is found that the axial runout has a significant influence on the surface topography generation. Furthermore, the influence of axial runout on the surface micro topography was studied quantitatively, and a critical axial runout is given for variable feed per tooth to generate specific surface topography. Finally, the proposed model is validated by means of experiments and a good correlation is obtained. The proposed surface generation model offers a basis for designing and optimizing surface parameters of functional machined surfaces.
[1] K Cheng, D Huo. Micro cutting: fundamentals and applications. Wiley, Chichester, 2013.
[2] X Liu, R DeVor, S Kapoor, et al. The mechanics of machining at the microscale: Assessment of the current state of the science. Journal of Manufacturing Science & Engineering, 2004, 126: 666-678.
[3] S Bruschi, et al. Environmentally clean micromilling of electron beam melted Ti6Al4V. Journal of Cleaner Production, 2016(133): 932-941.
[4] Wei Li, Zhixiong Zhou, Bi Zhang, et al. A micro-coupling for micro mechanical systems. Chinese Journal of Mechanical Engineering, 2016, 29(3): 571-578.
[5] Xuefeng Wu, Gaocheng Feng, Xianli Liu. Design and implementation of a system for laser assisted milling of advanced materials. Chinese Journal of Mechanical Engineering, 2016, 29(5): 921-929.
[6] David J Guckenberger, et al. Micromilling: a method for ultra-rapid prototyping of plastic microfluidic devices. Lab on a Chip, 2015, 15(11): 2364-2378.
[7] H Andersson, A Van. Microfluidic devices for cellomics: a review. Sensors and Actuators B: Chemical, 2003, 92(3): 315-325.
[8] I Ogilvie, V Sieben, C Floquet, et al. Reduction of surface roughness for optical quality microfluidic devices in PMMA and COC. Journal of Micromechanics and Microengineering, 2010, 20(6): 065016.
[9] H Becker, L E Locascio. Polymer microfluidic devices. Talanta, 2002, 56(2): 267-287.
[10] A Sodemann, M Li, R Mayor, et al. Micromilling of molds for microfluidic blood diagnostic devices. Proc. Annu. Meet Am. Soc. Precis. Eng., 2009: 4-9.
[11] C Mishra, Y Peles. Cavitation in flow through a micro-orifice inside a silicon microchannel. Physics of Fluids, 2005, 17(1): 013601.
[12] C Kleinstreuer, J Koo. Computational analysis of wall roughness effects for liquid flow in micro-conduits. Journal of Fluids Engineering, 2004, 126(1): 1-9.
[13] R Lopes, R O Rodrigues, D Pinho, et al. Low cost microfluidic device for partial cell separation: micromilling approach. Industrial Technology (ICIT), 2015 IEEE International Conference on. IEEE, 2015: 3347-3350.
[14] M Ali. Fabrication of microfluidic channel using micro end milling and micro electrical discharge milling. International Journal of Mechanical and Materials Engineering, 2009, 4(1): 93-97.
[15] V M ogler, R DeVor, S Kapoor. On the modeling and analysis of machining performance in micro-endmilling, Part I: Surface generation. Journal of Manufacturing Science and Engineering, 2004, 126(4): 685-694.
[16] S Oliaei, Y Karpat. Experimental investigations on micro milling of Stavax stainless steel. Procedia CIRP, 2014, 14: 377-382.
[17] G Bissacco, H N Hansen, L De Chiffre. Size effects on surface generation in micro milling of hardened tool steel. CIRP Annals-Manufacturing Technology, 2006, 55: 593-596.
[18] Y Sun, Y Liang, R Du. Simulation and analysis of surface generation in micro-milling. Proceedings of the 6th WSEAS International Conference on Robotics, Control and Manufacturing Technology, Hangzhou, China, 2006: 30-35.
[19] H Li, X Lai, C Li, et al. Modelling and experimental analysis of the effects of tool wear, minimum chip thickness and micro tool geometry on the surface roughness in micro-end-milling. Journal of Micromechanics and Microengineering, 2007, 18(2): 025006.
[20] H Weule, V Huntrup, H Tritschler. Micro cutting of steel to meet new requirements in miniaturization. CIRP Annals-Manufacturing Technology, 2001, 50: 61-64.
