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Investigation on the Size Effect and Cutting Force Coefficients in Micro End Milling Process
H. S. Kim(김홍석),I. S. Oh(오인식),J. W. Choi(최재욱) 한국소성가공학회 2013 금형가공 심포지엄 Vol.2013 No.9
With the global trend toward miniaturization, the demand of miniaturized components has significantly increased in a wide range of industries. As one of promising and suitable micro-manufacturing technologies, micro milling is widely used for the production of complex 3D shapes and geometries. In the micro milling operations, strong size effect occurs in the specific cutting energy due to the dominant ploughing forces and the increased feed per tooth to tool radius ratio. In order to understand the mechanics of micro milling process, this study proposes simple procedures to determine the instantaneous cutting force constants. The existing mechanistic model for predicting cutting forces in micro end milling demonstrated that the error between the predicted and measured values increased with decreasing uncut chip thickness. The curves for the instantaneous cutting force constants were thus calculated and fitted based on the experimental data to explain this scaling phenomenon and improve the prediction capability of the cutting force model. The experimental measurements showed a good agreement with the predicted cutting force values, and the effectiveness of the model and procedures can be confirmed.