Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling Article Swipe
Shuaishuai Gao
,
Xianyin Duan
,
Kunpeng Zhu
,
Yu Zhang
·
YOU?
·
· 2022
· Open Access
·
· DOI: https://doi.org/10.3390/mi13111805
YOU?
·
· 2022
· Open Access
·
· DOI: https://doi.org/10.3390/mi13111805
Accurate cutting force prediction is crucial in improving machining precision and surface quality in the micro-milling process, in which tool wear and runout are essential factors. A generic analytic cutting force model considering the effect of tool edge radius on tool flank wear and tool runout in the micro-end milling process is proposed. Based on the analytic modeling of the cutting part of the cutting edge in the end face of the micro-end mill bottom, the actual radius model of the worn tool is established, considering the tool edge radius and tool flank wear. The tool edge radius, tool wear, tool runout, trochoidal trajectories of the current cutting edge, and all cutting edges in the previous cycle are comprehensively considered in the instantaneous uncut chip thickness calculation and the cutter–workpiece engagement determination. The cutting force coefficient model including tool wear is established. A series of milling experiments are performed to verify the accuracy and effectiveness of the proposed cutting force model. The results show that the predicted cutting forces are in good agreement with the experimental cutting forces, and it is necessary to consider tool wear in the micro-milling force modeling. The results indicate that tool wear has a significant influence on the cutting forces and cutting force coefficients in the three directions, and the influences of tool wear on the axial cutting force and axial force coefficient are the largest, respectively. The proposed cutting force model can contribute to real-time machining process monitoring, cutting parameters optimization and ensuring machining quality.
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Metadata
- Type
- article
- Language
- en
- Landing Page
- https://doi.org/10.3390/mi13111805
- https://www.mdpi.com/2072-666X/13/11/1805/pdf?version=1667206864
- OA Status
- gold
- Cited By
- 14
- References
- 39
- Related Works
- 10
- OpenAlex ID
- https://openalex.org/W4307272718
All OpenAlex metadata
Raw OpenAlex JSON
- OpenAlex ID
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https://openalex.org/W4307272718Canonical identifier for this work in OpenAlex
- DOI
-
https://doi.org/10.3390/mi13111805Digital Object Identifier
- Title
-
Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End MillingWork title
- Type
-
articleOpenAlex work type
- Language
-
enPrimary language
- Publication year
-
2022Year of publication
- Publication date
-
2022-10-22Full publication date if available
- Authors
-
Shuaishuai Gao, Xianyin Duan, Kunpeng Zhu, Yu ZhangList of authors in order
- Landing page
-
https://doi.org/10.3390/mi13111805Publisher landing page
- PDF URL
-
https://www.mdpi.com/2072-666X/13/11/1805/pdf?version=1667206864Direct link to full text PDF
- Open access
-
YesWhether a free full text is available
- OA status
-
goldOpen access status per OpenAlex
- OA URL
-
https://www.mdpi.com/2072-666X/13/11/1805/pdf?version=1667206864Direct OA link when available
- Concepts
-
Enhanced Data Rates for GSM Evolution, Tool wear, Machining, Mechanical engineering, RADIUS, Flank, End milling, End mill, Milling cutter, Process (computing), Engineering, Cutting tool, Structural engineering, Computer science, Operating system, Sociology, Anthropology, Telecommunications, Computer securityTop concepts (fields/topics) attached by OpenAlex
- Cited by
-
14Total citation count in OpenAlex
- Citations by year (recent)
-
2025: 6, 2024: 4, 2023: 4Per-year citation counts (last 5 years)
- References (count)
-
39Number of works referenced by this work
- Related works (count)
-
10Other works algorithmically related by OpenAlex
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