Академический Документы
Профессиональный Документы
Культура Документы
Micro Engineering Dynamics Automation Laboratory (MEDAL), Department of Mechanical and Manufacturing Engineering,
University of Calgary, 2500 University Dr. NW, Calgary, Alberta, Canada T2N 1N4
Laboratory for Advanced Multi-scale Manufacturing, Department of Mechanical Engineering, University of Victoria,
PO Box 3055 STN CSC, Victoria, British Columbia, Canada V8W 3P6
b
a r t i c l e in f o
a b s t r a c t
Article history:
Received 14 May 2008
Received in revised form
10 February 2009
Accepted 14 February 2009
Available online 9 March 2009
This paper investigates the mechanistic modeling of micro-milling forces, with consideration of the
effects of ploughing, elastic recovery, run-out, and dynamics. A ploughing force model that takes the
effect of elastic recovery into account is developed based on the interference volume between the tool
and the workpiece. The elastic recovery is identied with experimental scratch tests using a conical
indenter. The dynamics at the tool tip is indirectly identied by performing receptance coupling analysis
through the mathematical coupling of the experimental dynamics with the analytical dynamics. The
model is validated through micro end milling experiments for a wide range of cutting conditions.
& 2009 Elsevier Ltd. All rights reserved.
Keywords:
Micro-machining
Cutting forces
Receptance coupling
Ploughing
1. Introduction
Highly accurate miniaturized components that are made up
of a variety of engineering materials play key roles in the
future development of a broad spectrum of products [1]. Many
innovative products require higher functionality with signicantly
decreased size; however, conventional fabrication methods using
photolithographic fabrication methods are not applicable to all
engineering materials, and the processes are slow and expensive
and limited to essentially planar geometries [2]. To overcome the
challenges, micro-mechanical machining processes can be utilized
to remove materials mechanically using a miniature tool to create
complex three-dimensional shapes using a variety of engineering
materials [3,4]. Micro-mechanical machining techniques bring
many advantages to the fabrication of micro-sized features. They
can produce micro-components cost-effectively because there is
no need for expensive photolithographic masks. The exibility and
efciency of micro-machining processes using miniature cutting
tools allows for the economical fabrication of smaller batch sizes
compared with other processes [5].
Due to the miniature nature of the mechanical removal
process, micro-machining operations are susceptible to excessive
tool wear, noise, and poor productivity. Thus, the modeling
and understanding of micro-cutting processes are important to
improve the machined part quality and increase productivity.
Corresponding author. Tel.: +1 4303 220 6959; fax: +1 403 282 8406.
ARTICLE IN PRESS
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
Nomenclature
Ap
dx, dy
e
ft
Ft
Fr
Fexp
Ftheo
h
hc
her
Krc, Ktc
Kre, Kte
Krp, Ktp
N
pe
re
r0
Vp
Xc, Yc
G
H
D
y
ce
ct, cs
587
2. Experimental setup
We have utilized an ultra precision vertical CNC milling
machine (Kern Micro 2255) with a spindle that can rotate from
60,000 to 160,000 rev/min (rpm). The base of the machine is
polymer concrete, which damps out external vibrations. Unlike
many micro CNC systems, the CNC machine used in this study
utilizes hybrid ball bearings, which provide higher stiffness
and linearity, and an elaborate lubrication system that allows
for temperature stability during the high-speed rotations. The
accuracy of the stage is 1 mm. The experimental setup for this
study is depicted in Fig. 1.
The micro-tools used in this study were uncoated tungsten
carbide (WC) micro end mills with 500 mm diameter at micro
end mills (PMT TS-2-0200-S) with the helix and clearance angles
of approximately 301 and 101, respectively. The tool overhang
length was 15 mm from the collet; and, this value remained
constant so that the dynamics were not changed during the
experiments. The scanning electron microscopy (SEM) picture of
the tip of the 500 mm diameter carbide end mill is shown in Fig. 2.
The edge radius of the tools was measured from the SEM pictures
and observed to be approximately 2 mm.
Several sensors, such as a table dynamometer, an acoustic
emission sensor, accelerometers and capacitance sensors, and an
optical vision system were used to capture various signals and
monitor the cutting processes. The piezo-electric table dynamometer (Kistler 9256C2) with an accuracy of 0.002 N measured
the micro-cutting forces. The charge signals generated from the
force sensor were fed into the charge ampliers (Kistler 9025B),
which converted the charge signals into voltage signals. The
calibration of the table dynamometer was performed using both
modal impact hammer tests (Dytran 5800SL) and a force gauge
(Omega DFG51-2) to verify the force measurement. The sensitivity
of the dynamometer was 26 pC/N for X and Y directions. The noise
level was approximately 0.005 N which was insignicant compared to the cutting forces. The frequency bandwidth of the
dynamometer was found to be approximately 1500 Hz (Fig. 3)
from the impact hammer tests.
The zero point in the Z direction was found by moving
the rotating tool down very slowly and looking at the acoustic
emission (AE) signal carefully. As soon as the tool touched the
workpiece, a sudden jump in the AE signal was observed, and
the position was set to zero. The forces were preprocessed by
subtracting air cutting forces from the measured cutting forces
through synchronization at each revolution of the spindle using
ARTICLE IN PRESS
588
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
Spindle
Capacitance Sensor
Workpiece
MiteeTM Grip
Accelerometer
Interface
AE Sensor
Z
Table Dynamometer
X
XY Stage
Magnitude [N/N]
15
10
3. Cutting force model
Bandwidth
1
0
0
1000
2000
3000 4000
Frequency [Hz]
5000
6000
7000
A mechanistic model has been developed to predict micromilling forces for both shearing and ploughing-dominant cutting
regimes. The model assumes that there is a critical chip thickness
that determines whether a chip will form or not. When machining
is performed at high feed rates, the effects of ploughing and elastic
recovery are insignicant enough to ignore, and the cutting
mechanism is considered to be shearing [10]. However, at lower
feed rates, these effects are substantial and need to be taken into
account. As a result, two different cutting regimes have been
dened. Since the cutting forces in the axial direction are small
compared with the planar directions, only the forces in the X and
Y directions have been considered in this study. The model has
been veried using experimental data for full and half immersion
cutting conditions.
In micro-machining, the edge radius of the tools is considerably large compared to the uncut chip thickness; as a result, the
so-called minimum chip thickness phenomenon occurs in micromachining. Thus, when the uncut chip thickness is less than the
minimum chip thickness (hc), no chip formation occurs and only
ploughing/rubbing takes place. Material separation occurs when
ARTICLE IN PRESS
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
h max0; kC ji F ji k kC ji Ij1
k.
i
Surface generated
from previous tooth path
hc
Surface generated
from current tooth path
Fig. 5. Chip thickness in the ploughing-dominant regime.
Tooth Path 1
h er
1
Fi
Micro-Endmill
Si+1
Ii
0
Ii+1
i+1
h
D
Ci
Ci+1
The mechanistic micro-milling forces are obtained by considering both the ploughing and shearing effects when the feed rate is
less than the critical chip thickness. We rst determine the
1
Si
Si
Fi+1
h
Surface generated
Surface to be generated
from tooth path 1
(1)
Shearing
Dominant
Regime
Tooth Path 1
the uncut chip thickness is greater than the critical minimum chip
thickness (hc), or at what is sometimes referred to as the
stagnation point [25,26], when the material above the minimum
chip thickness forms a chip and the material below the minimum
chip thickness deforms under the edge with a partial elastic
recovery, resulting in material ploughing. The edge radius of the
tool was 2 mm, and it has been shown that the critical chip
thickness for aluminum is approximately 0.3 of the edge radius
[27,28]. As a result, the critical chip thickness is considered to be
approximately 0.7 mm in this study.
We considered a helix angle of 301 when we discretized the
axial slices in the axial direction. Fig. 4 shows the ploughing
process at the ith rotational angle in micro end milling, when
the chip thickness is less than the minimum chip thickness for an
arbitrary axial slice, where yi represents the angles at the ith
rotational angle, h is the uncut chip thickness, her is the height
of elastic recovery, re is the edge radius, ce is the clearance angle,
and Ap is the ploughed area (represented by the hatched area)
at the rotational angle. The shaded area represents the ploughed
material. The ploughed volume, Vp, at the rotational angle, yi, can
be obtained by summing up the ploughed areas (Ap) of all the
axial slices along the cutting edge.
When the chip thickness, h, increases to greater than the
minimum chip thickness, hc, the ploughing becomes negligible,
and the elastic recovery drops to zero (Fig. 5). Thus, in micro end
milling, each ute goes through different material removal
mechanisms in a single path, and the cutting mechanisms switch
back and forth from the ploughing-dominant regime to the
shearing-dominant regime [28], depending on the uncut chip
thickness value, as shown in Fig. 5.
A comprehensive chip thickness model was developed in [15]
to compute the correct chip thickness, including the effects of the
trochoidal tool path, minimum chip thickness, elastic recovery,
and tool vibrations. Fig. 6 shows the surface generation and chip
thickness computation in the presence of elastic recovery, which
is represented as the shaded region, for an arbitrary axial slice.
Points C and F represent the tool centre and cutting edge locations,
respectively. The superscript denotes the tooth pass number, and
the subscript represents the rotational angle. Point I is found at
the intersection between the previously generated surface from
the previous tooth pass and the line connecting C and F for the
current tooth pass. The chip thickness can be formulated as [15]
589
Tool at i
Ploughed Material
re
her
Ploughed Area Ap
Fig. 4. Ploughing due to the nite edge radius in micro end milling.
ARTICLE IN PRESS
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
X1
H11 H12 H22 H33 1 H21
F1
o2n;i =ki
o2n;i o2 2zi on;i jo
i1
2
X
(4)
x 105
(2)
=
) fX1 g H11 fF1 g
h11;mf h11;mm
y1
M1
Experimental
3
Real [m/N]
590
Curve fitted
2
1
0
1
2
0
1000
2000
3000
5000
6000
5000
6000
4000
x 105
x3
Sub. B
2
x1
M3
Sub. A
M2
f3
f2
Imaginary [m/N]
x2
Experimental
1
0
1
2
3
0
f1
Curve fitted
1000
2000
3000
4000
Frequency [Hz]
Fig. 8. Receptance coupled dynamics (G11) at the tool tip for the 500 mm tool.
ARTICLE IN PRESS
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
3.5
Table 1
Dynamical parameters for the tool tip.
k (MN/m)
Second mode
4035
0.016
2.1425
5163
0.038
0.5397
3
2.5
F [N]
minimization of the error between the theoretical and experimentally obtained FRFs using the steepest descent method. The
rst and second modes occur at approximately 4035 and 5163 Hz,
respectively. This dynamic model of the tool allows us to take the
deection of the tool into account during the chip formation
process. If the frequency of the forces are close the natural
frequencies of the system, the forced vibration can be signicant
and immensely affect the micro-cutting operation and surface
generation. It has been assumed that the dynamics of the tool are
equivalent in the X and Y directions, since the tool and spindle
have cylindrical symmetry.
The dynamics of the tool can be utilized to nd the deection
of the tool due to the cutting forces. This deection affects the
surface generation and the cutting forces. If the cutting operation
occurs only in the X direction, the coordinates of the centre of the
end mill can be obtained from:
X Ci f t N
D
60
t i r 0 sin yi dxi ;
Y C i r 0 cos yi dyi
(5)
1.5
Shearing Dominant
Transition
First mode
Ploughing Dominant
on (Hz)
591
1
0.5
0
0
4
6
Feed Rate [m/flute]
10
Fig. 9. Micro-milling resultant forces vs. feed rates at full immersion with depth of
cut of 100 mm.
and, Kre and Kte are the radial and tangential edge coefcients,
respectively. The cutting coefcients represent shearing of the
workpiece, and the edge components represent friction between
the tool and the workpiece. In order to come up with the microcutting force model for the shearing-dominant regime, the
identication of cutting constants is imperative. These coefcients
are obtained from the experimental data; therefore the accurate
measurement of the cutting forces is important. Since the
frequency bandwidth of the table dynamometer is not sufcient
for high-speed cutting operations (i.e. 1500 Hz), the measured
cutting forces are need to be compensated for the unwanted
dynamics of the table dynamometer. A Kalman lter method is
employed as outlined in [34] to accurately measure the highspeed cutting forces based on the dynamics of the sensor as
shown in Fig. 3.
Since the uncut chip thickness is usually bigger than the
critical chip thickness when the feed rate is higher than a critical
value, the cutting mechanism is mainly shearing, and the effect
of ploughing can be neglected. This critical feed rate can
be identied from the forces in this shearing-dominant regime.
Fig. 9 shows the root mean square (RMS) value of the resultant
force vs. feed rate. As can be observed, for feed rates larger than
approximately 2.5 mm/ute, the force has a linear trend. A linear
curve t of the forces in this region is also shown in this gure. In
the ploughing-dominant regime, the forces have increased values
and vary smoothly, but do not follow the same linear behaviour
and are bigger than the predicted values by the extrapolated
linear curve t (dashed line in Fig. 9). A transition region between
the ploughing and shearing regions has been dened, in which
the forces do not follow a smooth curve. The force data in the
shearing-dominant regime can be used to obtain the cutting and
edge coefcients. Since the micro end mills generally have two
utes, the average of the forces is nearly zero, and the ordinary
method [33] of nding the coefcient does not work. Therefore,
the cutting coefcients are found via a nonlinear curve tting. For
this purpose, the following error is minimized through a steepest
descent algorithm [35]:
e
n X
m
X
F expi;j F theo 2
(8)
i1 j1
(7)
where dz is the height of the differential ute element; Krc and Ktc
are the radial and tangential cutting coefcients, respectively;
where n is the number of feed rates considered in the shearingdominant region, m is the number of samples, Fexp is the
instantaneous experimental forces data (stars in Fig. 9), and Ftheo
ARTICLE IN PRESS
592
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
Table 2
The cutting constants for the shearing dominant regime.
Parameter
Ktc (N/mm2)
Krc (N/mm2)
Kte (N/mm)
Kre (N/mm)
Al 6061
3650
2420
0.9
0.7
Experiment
coefcients, can appropriately predict the forces in the shearingdominant region. However, it is unable to account for the
increased forces at lower feed rates, and another model for this
ploughing-dominant region needed to be developed.
Simulation
Experiment
Simulation
Fy [N]
Fx [N]
1
1
2
3
2
4
4
0
200
400
400
600
Angle [Degree]
12
15
10
8
Magnitude
Magnitude
200
Simulation
6
Experiment
10
Simulation
Experiment
2
0
0
0
2000
4000
6000
Frequency [Hz]
8000
10000
2000
4000
6000
Frequency [Hz]
Fig. 10. Comparison of forces between experiments and simulation at full immersion and a feed rate of 9 mm/ute.
8000
10000
ARTICLE IN PRESS
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
2
Experiment
Experiment
Simulation
Simulation
Fy [N]
Fx [N]
1
2
0
1
2
3
4
3
0
200
600
400
200
10
400
600
6
5
Magnitude
Magnitude
593
Simulation
Experiment
4
2
Simulation
Experiment
3
2
1
0
0
2000
4000
6000
8000
10000
2000
Frequency [Hz]
4000
6000
8000
10000
Frequency [Hz]
Fig. 11. Comparison of forces between experiments and simulation at half immersion and a feed rate of 9 mm/ute: (a) X and (b) Y.
Tool at i
Tool at i
re
e
t
re
A
h
C
D
her
her
Fig. 12. Ploughing area for two different cases: (a) herXre(1cos ce) and (b) herore(1cos ce).
For both cases, point B represents the centre of the circle or the
rounded edge, and point D the end of the arc. Line lBD is at the
same angle as the clearance angle from the vertical line. Point A is
at the height of the elastic recovery.
When herXre(1cos ce), the ploughed area, Ap, indicated by the
shaded area in Fig. 12(a), can be obtained as
Ap ABCD AABD AABC
(10)
where ABCD is the area of the arc segment, and AABD and AABC are
the areas of the triangles connecting the corresponding points.
Area ABCD can be obtained by
ABCD 12r 2e ap ce
The area AABD is given by
r e her r e 1 cos ce
12r e lAD
AABD
sin ce
2
her r e 1 cos ce
where lAD
sin ce
(11)
(14)
(15)
(16)
where
cs cos1 1
(12)
where
q
2
lAB r 2e lAD
l
ct tan1 AD
re
(13)
her
re
(17)
ARTICLE IN PRESS
594
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
(18)
dF tp K tp Ap K te dz
where Krp and Ktp are the radial and tangential ploughing coefcients, respectively, and Ap can be determined from Eqs. (15) or
(16). The ploughing coefcients represent ploughing of the
workpiece material. Kre and Kte are the same edge coefcients
as in Eq. (7). Since the edge coefcients represent friction as the
uncut chip thickness goes to zero, the edge components in
the ploughing-dominant regime must be the same as those in the
shearing-dominant regime. The unit for the ploughing coefcients
is N/mm3.
C
b
B
Fig. 13. Finding elastic recovery through an indentation test using a conical
indenter.
Table 3
The cutting constants and estimated parameter values for the ploughing-dominant
regime.
Parameter
Ktp (kN/mm3)
Krp (kN/mm3)
ro (mm)
pe (%)
Al 6061
790
1210
0.2
10
Simulation
0.4
K rc h K re dz
K rp Ap K re dz
0.4
Experiment
(19)
Simulation
Experiment
0.2
Fy [N]
Fx [N]
where h f(ft, y, her, dx, dy, ro), Ap f(h, re, her), ft is the feed per
tooth, and y is the rotational angle of the tool. The computed
forces are summed among all the engaged axial slices over all the
cutting utes to obtain the total tangential and radial forces,
which are then transformed to forces in the planar directions,
with respect to the global coordinate system. The proposed model
suggests cutting and ploughing coefcients that inherently
contain different aspects of plastic deformation, such as strain
hardening and strain gradient effects. The friction forces are
considered constant for different conditions and modeled with
the edge coefcients.
When the uncut chip thickness is smaller than the critical
value, an elastic recovery occurs that can affect the chip
formation, cutting forces, and surface generation during machining operations. The elastic recovery is different for various
materials and should be identied in order to accurately model
the micro-machining operations. It has been shown [41] that the
elastic recovery rate of the material can be identied directly
using instrumented conical scratch tests. In this method, the
remaining grooves from the scratch tests are inspected using a
0.2
0
0.2
0
0.2
0.4
0.4
0.6
0.6
0.8
0.8
0
200
400
600
1.5
1.5
Magnitude
Magnitude
K tc h K te dz
K tp Ap K te dz
Simulation
Experiment
200
400
600
Simulation
Experiment
0.5
0.5
0
0
2000
4000
6000
Frequency [Hz]
8000
10000
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Frequency [Hz]
Fig. 14. Comparison of forces between experiments and simulation at full immersion and a feed rate of 0.5 mm/ute.
ARTICLE IN PRESS
0.4
0.2
0
0.2
0.4
0.6
0.8
Simulation
Simulation
0.4
Experiment
0.2
0
0.2
0.4
200
400
600
200
400
2
Magnitude
2.5
Magnitude
595
0.6
Experiment
Fy [N]
Fx [N]
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
2
Simulation
1.5
Experiment
1.5
Simulation Experiment
1
0.5
0.5
0
0
0
2000
6000
4000
Frequency [Hz]
8000
10000
2000
4000
6000
8000
10000
Frequency [Hz]
Fig. 15. Comparison of forces between experiments and simulation at half immersion and a feed rate of 0.5 mm/ute.
0.12
Fx [N]
Magnitude
0.1
0.08
2
Experimental Data
Linear Curve Fit
Simulation
0.06
0
0.04
10
10
0
0
2000
4000
6000
Frequency [Hz]
8000
10000
Fy [N]
0.02
2
Fig. 16. FFT of the AE signal for full immersion and a feed rate of 0.5 mm/ute.
SABC Sabc
SABC
(20)
6
4
Feed Rate [m/flute]
Fig. 17. Comparison of the RMS of data between experiments and simulation for
full immersion.
ARTICLE IN PRESS
596
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
Simulation
r0 = 1
0
0.5
0.5
0
200
400
600
Experiment
800
Simulation
r0 = 0.2
Simulation
r0 = 0
200
0.5
Fy [N]
0.5
Fy [N]
Simulation
r0 = 0.2
Experiment
0.5
Fx [N]
Fx [N]
Simulation
r0 = 0
Simulation
r0 = 0.2
Experiment
0.5
0.5
400
600
800
Experiment
Simulation
r0 = 1
0
0.5
200
400
600
800
200
400
600
Angle [Degree]
800
Angle [Degree]
Fig. 18. Comparison of forces between experiments and simulation at full immersion and a feed rate of 0.5 mm/ute for different run-outs: (a) r0 0 and 0.2 mm and (b)
r0 0.2 and 1 mm.
Experiment
Simulation
Pe=10%
Simulation
Pe=0%
0.5
Fx [N]
Fx [N]
0.5
0
Simulation
Pe=10%
0
0.5
0.5
0
200
400
600
Experiment
800
Simulation
Pe=10%
0
0.5
200
400
600
Experiment
0.5
Simulation
Pe=0%
Fy [N]
0.5
Fy [N]
Simulation
Pe=20%
Experiment
800
Simulation
Pe=20%
Simulation
Pe=10%
0
0.5
200
400
600
200
400
600
Fig. 19. Comparison of forces between experiments and simulation at full immersion and a feed rate of 0.5 mm/ute for different elastic recoveries: (a) Pe 0% and 10% and
(b) Pe 10% and 20%.
ARTICLE IN PRESS
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
0.30
0.25
4. Discussions
0.20
alim [mm]
597
0.15
0.10
0.05
0
0
4
6
Spindle Speed [rev/min]
10
x 104
Fig. 20. Regenerative chatter stability lobes for full immersion micro-milling of
Al6061.
5. Conclusion
The accurate prediction of micro-milling forces is important in
the determination of the optimal machining parameters, in order
to prevent excessive tool wear and poor surface nish while
maintaining high productivity. Unlike macro machining operations, ploughing occurs in micro-machining operations when the
chip thickness is less than the critical chip thickness. There have
been attempts by other researchers to include the effects of
ploughing, elastic recovery and the minimum chip thickness,
based on slip-line plasticity or nite element modeling. However,
these models are very complex, and the estimation of the many
parameters in the models is difcult. In this paper, a mechanistic
force model is developed for the ploughing and shearingdominant regimes for micro end milling operations, considering
run-out, dynamics and the effects of the elastic recovery of
material commonly encountered during micro-machining. Since
the direct measurement of tool tip dynamics is not feasible, we
have employed the receptance coupling method to indirectly
obtain the dynamics. The mechanistic force model has been
veried with experimental cutting force measurements of
Aluminum 6061.
Acknowledgements
This research was supported by the Natural Sciences and
Engineering Research Council of Canada (NSERC), Auto21, and
Canada Foundation for Innovation (CFI). The authors thank Mr.
Abe from Mitsubishi Materials, Japan and Mr. Aarts from Jabro
(Seco) Tools, Netherlands for their generous support.
References
[1] W. Ehrfeld, U. Ehrfeld, Progress and prot through micro technologies.
Commercial applications of MEMS/MOEMS, Proceedings of the SPIE 4561
(2001) 918.
[2] W. Menz, J. Mohr, O. Paul, Microsystem Technology, Wiley-VCH, 2001.
[3] D. Dornfeld, S. Min, T. Takeuchi, Recent advances in mechanical micromachining, Annals of the CIRP 55 (2) (2006) 745768.
[4] Y. Bang, K. Lee, S. Oh, 5-Axis micro milling machine for machining micro parts,
International Journal of Advanced Manufacturing Technology 25 (910)
(2005) 888894.
[5] J. Chae, S.S. Park, T. Freiheit, Investigation of micro-cutting operations,
International Journal of Machine Tools and Manufacture 46 (34) (2006)
313332.
ARTICLE IN PRESS
598
M. Malekian et al. / International Journal of Machine Tools & Manufacture 49 (2009) 586598
[6] G. Bissacco, H.N. Hansen, J. Slunsky, Modelling the cutting edge radius size
effect for force prediction in micro milling, Annals of the CIRP 57 (1) (2008)
113116.
[7] H. Weule, V. Huntrup, H. Tritschle, Micro-cutting of steel to meet new
requirements in miniaturization, Annals of the CIRP 50 (1) (2001) 6164.
[8] X. Lai, H. Li, C. Li, Z. Lin, J. Ni, Modelling and analysis of micro scale milling
considering size effect, micro cutter edge radius and minimum chip thickness,
International Journal of Machine Tools and Manufacture 48 (2008) 114.
[9] M.P. Vogler, S.G. Kapoor, R.E. DeVor, On the modeling and analysis of
machining performance in micro end milling, part II: cutting force prediction,
ASME Journal of Manufacturing Science and Engineering 126 (4) (2004)
695705.
[10] M.P. Vogler, R.E. DeVor, S.G. Kapoor, On the modeling and analysis of
machining performance in micro end milling, part I: surface generation,
ASME Journal of Manufacturing Science and Engineering 126 (4) (2004)
685694.
[11] E.J.A. Armarego, R.H. Brown, On size effect in metal cutting, International
Journal of Production Research 1 (3) (1962) 7599.
[12] D.A. Lucca, R.L. Rhorer, R. Komanduri, Energy dissipation in the ultraprecision
machining of copper, Annals of the CIRP 40 (1) (1991) 6972.
[13] R. Komanduri, Some aspects of machining with negative rake tools simulating
grinding, International Journal of Machine Tool Design 11 (3) (1971) 223233.
[14] D.J. Waldorf, R.E. DeVor, S.G. Kapoor, Slip-line eld for ploughing during
orthogonal cutting, ASME Journal of Manufacturing Science and Engineering
120 (4) (1988) 693698.
[15] M.B.G. Jun, X. Liu, R.E. DeVor, S.G. Kapoor, Investigation of the dynamics of
micro end milling, part 1: model development, ASME Journal of Manufacturing Science and Engineering 128 (4) (2006) 893900.
[16] N. Fang, Slip-line modeling of machining with a rounded-edge tool-part I:
new model and theory, Journal of the Mechanics and Physics of Solids 51 (4)
(2003) 715742.
[17] K. Liu, S.N. Melkote, Material strengthening mechanisms and their contribution to size effect in micro-cutting, ASME Journal of Manufacturing Science
and Engineering 128 (3) (2006) 730738.
[18] K.W. Kim, W.Y. Lee, H.C. Sin, Finite element analysis for the characteristics of
temperature and stress in micro-machining considering the size effect,
International Journal of Machine Tools and Manufacture 39 (9) (1999)
15071524.
[19] T. Ozel, E. Zeren, Finite element modeling of stresses induced by high speed
machining with round edge cutting tools. 2005 ASME International Mechanical Engineering Congress and Exposition, IMECE 2005, November 511, 2005,
Orlando, FL, USA, 2005.
[20] J. Rech, Y.-C. Yen, M.J. Schaff, H. Hamdi, T. Altan, K.D. Bouzakis, Inuence of
cutting edge radius on the wear resistance of Pm-Hss milling inserts, Wear
259 (712) (2005) 11681176.
[21] M.T. Zaman, A.S. Kumar, M. Rahman, S. Sreeram, A three-dimensional
analytical cutting force model for micro end milling operation, International
Journal of Machine Tools and Manufacture 46 (34) (2006) 353366.
[22] W.Y. Bao, I.N. Tansel, Modeling micro end-milling operations. Part I: analytical
cutting force model, International Journal of Machine Tools and Manufacture
40 (15) (2000) 21552173.
[23] I.S. Kang, J.S. Kim, J.H. Kim, M.C. Kang, Y.W. Seo, A mechanistic model of
cutting force in the micro end milling process, Journal of Materials Processing
Technology 187188 (2007) 250255.
[24] H.U. Lee, D.W. Cho, K.F. Ehmann, A mechanistic model of cutting forces in
micro-end-milling with cutting-condition-independent cutting force coefcients, ASME Journal of Manufacturing Science and Engineering 130 (3)
(2008) 03110210311029.
[25] R. Connolly, C. Rubenstein, The mechanics of continuous chip formation in
orthogonal cutting, International Journal of Machine Tool Design and
Research 8 (1968) 159187.
[26] I.S. Jawahir, K.C. Ee, O.W. Dillon Jr., Finite element modeling of residual
stresses in machining induced by cutting using a tool with nite edge
radius, International Journal of Mechanical Sciences 47 (10) (2005)
16111628.
[27] P.K. Basuray, B.K. Misra, G.K. Lal, Transition from ploughing to cutting during
machining with blunt tools, Wear 43 (3) (1977) 341349.
[28] M. Malekian, S.S. Park, Investigation of micro milling forces for aluminum,
Transactions of SME-NAMRI 35 (1) (2007) 417424.
[29] B.A. Mascardelli, S.S. Park, T. Freiheit, Substructure coupling of micro end
mills. ASME International Mechanical Engineering Congress and Exposition,
IMECE2006. Chicago, IL, USA, 2006.
[30] T.L. Schmitz, G.S. Duncan, Receptance coupling for dynamics prediction of
assemblies with coincident neutral axes, Journal of Sound and Vibration 289
(2006) 10451065.
[31] A. Erturk, H.N. Ozguven, E. Budak, Analytical modeling of spindle-tool
dynamics on machine tools using Timoshenko beam model and receptance
coupling for the prediction of tool point FRF, International Journal of Machine
Tools and Manufacture 46 (15) (2006) 19011912.
[32] S.S. Park, Y. Altintas, M. Movahhedy, Receptance coupling for end mills,
International Journal of Machine Tools and Manufacture 43 (9) (2003)
889896.
[33] Y. Altintas, Manufacturing Automation, Cambridge University Press, 2000.
[34] Y. Altintas, S.S. Park, Dynamic compensation of spindle integrated force
sensors, Annals of CIRP 53 (1) (2004) 305309.
[35] P.R. Adby, M.A.H. Dempster, Introduction to Optimization Methods, Chapman
& Hall, London, 1974.
[36] D.W. Wu, A new approach of formulating the transfer function for dynamic
cutting processes, ASME Journal of Engineering for Industry 111 (1989)
3747.
[37] W.J. Endres, R.E. DeVor, S.G. Kapoor, Dual-mechanism approach to the
prediction of machining forces, Part 1: model development, ASME Journal of
Engineering for Industry 117 (4) (1995) 526533.
[38] A.M. Shawky, M.A. Elbestawi, Enhanced dynamic model in turning including
the effect of ploughing forces, ASME Journal of Manufacturing Science and
Engineering 119 (1) (1997) 1020.
[39] M.A. Elbestawi, F. Ismail, R. Du, B.C. Ullagaddi, Modelling machining
dynamics including damping in the toolworkpiece interface, ASME Journal
of Engineering for Industry 116 (4) (1994) 435439.
[40] M.B.G. Jun, R.E. DeVor, S.G. Kapoor, Investigation of the dynamics of micro
end milling, part 2: model validation and interpretation, ASME Journal of
Manufacturing Science and Engineering 128 (4) (2006) 901912.
[41] M. Malekian, S.S. Park, K. Um, Investigation of micro plowing forces
through conical scratch tests, Transactions of SME-NAMRI 36 (1) (2008)
293300.
[42] M.B.G. Jun, K. Bourne, R.E. DeVor, S.G. Kapoor, Estimation of effective error
parameters in high-speed micro-end milling, International Journal of
Machine Tools and Manufacture 47 (9) (2007) 14491454.