Modeling and Analysis of Micro -End Milling Dynamics

Experimental and analytical methods have been developed to estimate the values of the faults in micro-end milling. Experimental validation of the model has been performed, and the model is shown to predict cutting forces and micro-end mill deflections within an average of 15%. Effects of process faults on micro-end mill vibrations have been studied varying feedrates for which the cutting mechanisms vary from ploughing-dominated to shearing-dominated. The stability characteristics based on the regenerative effect that are unique in the micro-end mill have also been studied. Vibration contour maps have been generated to investigate the dynamic behavior of micro-end mills under different cutting mechanisms. The results show that the stability lobes from the second mode, which are generally neglected in macro-scale end milling, affect the micro-end mill stability significantly. The contour maps show that the minimum chip thickness effect has significant effect on the micro-end mill dynamic behavior at low feedrates where the process is ploughing-dominated. The model has also been applied and validated for a high-speed end milling process.

Name thesis:degree_name

Ph.D.

Level thesis:degree_level

Dissertation

Discipline thesis:degree_discipline

Mechanical Engineering

Grantor

University of Illinois at Urbana-Champaign

Year dc:date

2015

Author dc:creator

• Jun, Martin

Contributors dc:contributor

• Shiv Kapoor
• DeVor, Richard E.

• Engineering, Mechanical

Language dc:language

eng

Identifier

(MiAaPQ)AAI3182292

OAI identifier oai:identifier

oai:www.ideals.illinois.edu:2142/83825