Title: Modelling of process geometry and mechanics in micro-milling along straight and circular tool paths

Authors: Alwin Varghese; Vinay S. Kulkarni; Suhas S. Joshi

Addresses: Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai – 400076, India ' Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai – 400076, India ' Department of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai – 400076, India

Abstract: Real-life application of micro-milling often encounters tool-paths along straight and circular profiles, especially while pocketing and cutting round corners. Change in process geometry parameters, such as instantaneous uncut chip thickness and tool engagements with the workpiece while machining complex profiles, can lead to tool breakage, and therefore needs detailed investigation. This work, therefore, focuses on developing an analytical model to predict the process geometry parameters by considering tool runout and different tool-paths in micro-milling. It was observed from the model that the maximum uncut chip thickness exceeds by 9%, while machining along circular tool-path when compared to that along straight tool-path at the same feed. Further, the rate of increase in entry and exit angles was found to be larger for smaller tool-path radii. The cutting forces predicted using the uncut chip thickness evaluated from the model lies within 10% error of that of experimentally measured cutting forces.

Keywords: micro-milling; circular tool paths; uncut chip thickness; modelling; micro cutting mechanics.

DOI: 10.1504/IJMMS.2021.121246

International Journal of Mechatronics and Manufacturing Systems, 2021 Vol.14 No.3/4, pp.266 - 288

Received: 11 Jul 2021
Accepted: 21 Sep 2021
Published online: 01 Mar 2022 *

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