This paper investigates the mechanistic modeling of micro end milling forces, with consideration of the effects of plowing, elastic recovery, effective rake angle, and flank face rubbing. Two different mechanistic models are developed for shearing- and plowing-dominant regimes. Micro end milling experiments are conducted to validate the model for Aluminum 6061; and, the model appropriately predicts force profiles for a wide range of feed rates, and prediction of the root mean square (RMS) values of the resultant forces is, on average, within a 12% error. The study of the model shows that plowing and rubbing force contributions are significant, especially at low feed rates. The edge radius is found to have a significant effect on plowing and rubbing force components and the effective rake angle, which indicates that it is important to maintain a low edge radius to reduce micro end milling forces.
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February 2012
Research Papers
A New Mechanistic Approach for Micro End Milling Force Modeling
Martin B. G. Jun,
Martin B. G. Jun
Assistant Professor
Department of Mechanical Engineering,
University of Victoria
, Victoria, BC, V8W 3P6
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Chanseo Goo,
Chanseo Goo
Graduate Student
Department of Mechanical Engineering,
University of Victoria
, Victoria, BC, V8W 3P6
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Mohammad Malekian,
Mohammad Malekian
Graduate Student
Department of Mechanical Engineering,
University of Calgary
, Calgary, AB, T2N 1N4
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Simon Park
Simon Park
Associate Professor
Department of Mechanical Engineering,
University of Calgary
, Calgary, AB, T2N 1N4
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Martin B. G. Jun
Assistant Professor
Department of Mechanical Engineering,
University of Victoria
, Victoria, BC, V8W 3P6
Chanseo Goo
Graduate Student
Department of Mechanical Engineering,
University of Victoria
, Victoria, BC, V8W 3P6
Mohammad Malekian
Graduate Student
Department of Mechanical Engineering,
University of Calgary
, Calgary, AB, T2N 1N4
Simon Park
Associate Professor
Department of Mechanical Engineering,
University of Calgary
, Calgary, AB, T2N 1N4J. Manuf. Sci. Eng. Feb 2012, 134(1): 011006 (9 pages)
Published Online: January 12, 2012
Article history
Received:
May 17, 2010
Revised:
October 21, 2011
Online:
January 12, 2012
Published:
January 12, 2012
Citation
Jun, M. B. G., Goo, C., Malekian, M., and Park, S. (January 12, 2012). "A New Mechanistic Approach for Micro End Milling Force Modeling." ASME. J. Manuf. Sci. Eng. February 2012; 134(1): 011006. https://doi.org/10.1115/1.4005429
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