Research On Cutting Forces Modeling And Test Of Micro Turn-milling

As the frontier of advanced manufacturing technology in the21st century, microturning-milling also considered as one of the most flexible cutting methods and has apromising prospect. micro turn-milling could meet the diversity requirements of shapesand materials of three-dimensional micro parts, which had more advantages.The rigidityof micro-milling cutter will decreases due to smaller diameter micro milling cuter,forthis reason,feed engagement in micro-turn-milling is limited in several micrometers oreven lower in order to extend tool life.With the reduction in the size of the tool, theround radius of cutting edge which has not been considered in conventional millingmust be considered; the round radius of micro milling cutter usually is in several micrometers,so feed per tooth in micro-turn-milling is equal to even smaller than the roundradius of micro milling cutter. Then as a result of friction, pressing or grooving of thework-piece from tool edge, the elastic-plastic deformation aggravates.This paper was based on the principle and technology of micro-cutting technology,and combined with characteristics in micro turn-milling, establish cutting force theoryanalytical model of micro turn-milling based on metal cutting theory and the elastic-pla-stic deformation theory.The influence of the plough force between the flank face ofcutter and the finished surface and the stress state of the rake face was considered oncutting force in this model.First of all,according to study different characteristics between conventional turn-milling and micro turn-milling,and analysed the cause of the existing conventionnalturn-milling cannot be directly applied to micro turn-milling. Meanwhile,the influenceof the tool edge radius、the uncut chip thickness and elastic recovery of flank face oncutting force in micro turn-milling and for the sake of establish a more accurate cuttingforce model of micro turn-milling.Secondly,the orthogonal cutting force model of micro-element edge was establish-ed, analysed elastoplastic deformation of metal cutting layer and the stress distributionon of cutting tool in cutting process.and then tool-workpiece shear zone and the normalstress and shear stress in finished surface of tool-workpiece. according to the orthogonal cutting theory,the cutting force model of micro-element edge was established and getthe whole cutting force by integrating the cutting force model of micro-element edge.Finally,the less experiment with the micro orthogonal turn-milling machine themicro-shaft was studied by the method of multi-factor orthogonal experiment.Itarranged experiments by the orthogonal table and draw a conclusion of the experimentaldata,and then dispose experimental data by analysis of variance and range,in order toensure the primary and secondary sequence of experimental factors influence onprocessed surface roughness and the optimum combination of experimental factors.