Improved dynamic cutting force modelling in micro milling of metal matrix composites Part I: Theoretical model and simulations

Cutting force modelling for micro machining is of great importance for better understanding of the cutting mechanics in the process. As precision machining of metal matrix composites (MMCs) is much more complex than machining homogeneous materials, the accurate prediction of cutting force is critica...

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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, 2020-05, Vol.234 (9), p.1733-1745
Main Authors: Niu, Zhichao, Cheng, Kai
Format: Article
Language:English
Subjects:
Chip formation
Computer simulation
Cutting force
End milling
Metal matrix composites
Micromachining
Milling (machining)
Modelling
Multiscale analysis
Precision machining
Process variables
Signal processing
Size effects
Tool life
Tooling
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Summary:Cutting force modelling for micro machining is of great importance for better understanding of the cutting mechanics in the process. As precision machining of metal matrix composites (MMCs) is much more complex than machining homogeneous materials, the accurate prediction of cutting force is critical to control the cutting performance and tooling life. This paper presents an improved theoretical dynamic cutting force model in MMCs micro milling process by using straight flute PCD end mills. The theoretical model is modified and improved based on the conventional milling force modelling while taking account of various factors including tooling geometries, the material microstructure, size effect and chip formation in the cutting process. An innovative expression on dynamic cutting force in micromachining MMCs is presented through the multiscale modelling and analysis. The cutting force coefficients are further defined through instantaneous cutting force signals analysis. Simulation results under varied cutting process variables are presented against a series of MMCs micro milling trials, which indicate that the improved dynamic cutting force model can predict the cutting force accurately and reveal more details on the cutting force variations in the process due to the material inhomogeneous nature. In addition, the optimal process variables can be readily explored through the dynamic force modelling and simulations so as to further improve the cutting performance.
ISSN:0954-4062
2041-2983
DOI:10.1177/0954406219899688