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Tool deflection model for micromilling processes

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Abstract

Research in micromilling processes has found that tool deflection phenomenon affects the forces significantly, causing a smoothing effect in the tool run-out. Therefore, this needed to be taken into account to design a model for reliably predicting the cutting forces in these processes. In this paper, a study of the tool deflection phenomenon was carried out by applying the principles of elasticity of materials to the situation of a tool under a distributed force along its edge. The contribution of this study consisted of considering a variable deflection along the length of the edge, which has not been taken into account in previous models. A new methodology of obtaining the rigidity, based on experimental data, was applied to two specific types of mills by using their geometry. With this model, a linear equations system that allows the prediction of cutting forces was obtained. These predictions, which were calculated with a low computational cost, can be used in monitoring systems and adaptive control of the process for the prevention of tool failure.

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Authors and Affiliations

  1. Department of Manufacturing Engineering, Industrial Engineering School, University of Leon, Campus de Vegazana s/n, 24071, León, Spain

    P. Rodríguez & J. E. Labarga

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  1. P. Rodríguez
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  2. J. E. Labarga
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Correspondence to P. Rodríguez.

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Rodríguez, P., Labarga, J.E. Tool deflection model for micromilling processes. Int J Adv Manuf Technol 76, 199–207 (2015). https://doi.org/10.1007/s00170-014-5890-8

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  • DOI: https://doi.org/10.1007/s00170-014-5890-8

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