Improved dynamic cutting force modelling in micro milling of metal matrix composites part II: Experimental validation and prediction

The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This compreh...

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Bibliographic Details
Published in:Proceedings of the Institution of Mechanical Engineers. Part C, Journal of mechanical engineering science Journal of mechanical engineering science, 2020-04, Vol.234 (8), p.1500-1515
Main Authors: Niu, Zhichao, Cheng, Kai
Format: Article
Language:English
Subjects:
Cutting force
Cutting parameters
Diamond machining
Dissolution
End milling
Kalman filters
Mathematical models
Metal matrix composites
Modelling
Polycrystalline diamond
Side milling
Temperature
Trajectory analysis
Workpieces
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Summary:The effects of cutting dynamics and the particles' size and density cannot be ignored in micro milling of metal matrix composites. This article presents the improved dynamic cutting force modelling for micro milling of metal matrix composites based on the previous analytical model. This comprehensive improved cutting force model, taking the influence of the tool run-out, actual chip thickness and resultant tool tip trajectory into account, is evaluated and validated through well-designed machining trials. A series of side milling experiments using straight flutes polycrystalline diamond end mills are carried out on the metal matrix composite workpiece under various cutting conditions. Subsequently, the measured cutting forces are compensated by a Kalman filter to achieve the accurate cutting forces. These are further compared with the predicted cutting forces to validate the proposed dynamic cutting force model. The experimental results indicate that the predicted and measured cutting forces in micro milling of metal matrix composites are in good agreement.
ISSN:0954-4062
2041-2983
DOI:10.1177/0954406219893725