In Part II of this paper, a cutting force model for the micro-endmilling process is developed. This model incorporates the minimum chip thickness concept in order to predict the effects of the cutter edge radius on the cutting forces. A new chip thickness computation algorithm is developed to include the minimum chip thickness effect. A slip-line plasticity force model is used to predict the force when the chip thickness is greater than the minimum chip thickness, and an elastic deformation force model is employed when the chip thickness is less than the minimum chip thickness. Orthogonal, microstructure-level finite element simulations are used to calibrate the parameters of the force models for the primary metallurgical phases, ferrite and pearlite, of multiphase ductile iron workpieces. The model is able to predict the magnitudes of the forces for both the ferrite and pearlite workpieces as well as for the ductile iron workpieces within 20%.
Skip Nav Destination
Article navigation
November 2004
Technical Papers
On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part II: Cutting Force Prediction
Michael P. Vogler, Graduate Student,
Michael P. Vogler, Graduate Student
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906
Search for other works by this author on:
Shiv G. Kapoor, Professor, Fellow ASME,
Shiv G. Kapoor, Professor, Fellow ASME
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906
Search for other works by this author on:
Richard E. DeVor, Professor, Fellow ASME
Richard E. DeVor, Professor, Fellow ASME
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906
Search for other works by this author on:
Michael P. Vogler, Graduate Student
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906
Shiv G. Kapoor, Professor, Fellow ASME
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906
Richard E. DeVor, Professor, Fellow ASME
Department of Mechanical and Industrial Engineering, University of Illinois at Urbana-Champaign, Urbana, IL 61801-2906
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February, 2003; revised March, 2004. Associate Editor: K. F. Ehman.
J. Manuf. Sci. Eng. Nov 2004, 126(4): 695-705 (11 pages)
Published Online: February 4, 2005
Article history
Received:
February 1, 2003
Revised:
March 1, 2004
Online:
February 4, 2005
Citation
Vogler, M. P., Kapoor, S. G., and DeVor, R. E. (February 4, 2005). "On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part II: Cutting Force Prediction ." ASME. J. Manuf. Sci. Eng. November 2004; 126(4): 695–705. https://doi.org/10.1115/1.1813471
Download citation file:
Get Email Alerts
Related Articles
On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part I: Surface Generation
J. Manuf. Sci. Eng (November,2004)
Dynamic Material Behavior Modeling Using Internal State Variable Plasticity and Its Application in Hard Machining Simulations
J. Manuf. Sci. Eng (August,2006)
The Mechanics of Machining at the Microscale: Assessment of the Current State of the Science
J. Manuf. Sci. Eng (November,2004)
A Geometrical Simulation System of Ball End Finish Milling Process and Its Application for the Prediction of Surface Micro Features
J. Manuf. Sci. Eng (February,2006)
Related Proceedings Papers
Related Chapters
Cutting Performance and Wear Mechanism of Cutting Tool in Milling of High Strength Steel 34CrNiMo6
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)
Modeling of Cutting Force in Vibration-Assisted Machining
Vibration Assisted Machining: Theory, Modelling and Applications
Analysis on Influence of the Tool Orthogonal Rake on Cutting Force, Temperature and Deformation
Proceedings of the 2010 International Conference on Mechanical, Industrial, and Manufacturing Technologies (MIMT 2010)