Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method

Micromilling is one of the preferable micro-manufacturing process, as it exhibits the flexibility to produce complex 3D micro-parts. The cutting forces generated in micro end milling can be attributed for tool vibration and process instability. If cutting forces are not controlled below critical lim...

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Autores principales:	Bhople Narendra, Mastud Sachin, Satpal Satish
Formato:	article
Lenguaje:	EN
Publicado:	EDP Sciences 2021
Materias:	cutting force finite element method micro-end milling tungsten carbide von-misses stress surface roughness ti-6al-4v Industrial engineering. Management engineering T55.4-60.8 Industrial directories T11.95-12.5
Acceso en línea:	https://doaj.org/article/d95436a46cec4f3299fb6ea1ac25a0df
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spelling	oai:doaj.org-article:d95436a46cec4f3299fb6ea1ac25a0df2021-11-08T15:22:40ZModelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method1779-628810.1051/smdo/2021027https://doaj.org/article/d95436a46cec4f3299fb6ea1ac25a0df2021-01-01T00:00:00Zhttps://www.ijsmdo.org/articles/smdo/full_html/2021/01/smdo210105/smdo210105.htmlhttps://doaj.org/toc/1779-6288Micromilling is one of the preferable micro-manufacturing process, as it exhibits the flexibility to produce complex 3D micro-parts. The cutting forces generated in micro end milling can be attributed for tool vibration and process instability. If cutting forces are not controlled below critical limits, it may lead to catastrophic failure of tool. Cutting force has a significant role to decide the surface roughness. Therefore accurate prediction of cutting forces and selection of suitable cutting parameters mainly feed, is important while micro end milling. In present study, finite element method (FEM) based model has been developed by using ABAQUAS/Explicit 6.12 software. Von-Misses stresses and cutting forces are predicted while micro end milling of Ti-6Al-4V. Further, cutting forces were measured during experimentation using dynamometer mounted on micro-milling test bed. Cutting forces predicted by FEM model are in good agreement with the experimental force values. Obtained FEM results have been used to study the size effect in micro end milling process. Moreover, the effect of uncut chip thickness to cutting edge radius ratio (h/rc) on surface roughness (Ra) has been studied. It is found the feed 2.5 µm/tooth is suitable value to produce optimum surface roughness and cutting forces.Bhople NarendraMastud SachinSatpal SatishEDP Sciencesarticlecutting forcefinite element methodmicro-end millingtungsten carbidevon-misses stresssurface roughnessti-6al-4vIndustrial engineering. Management engineeringT55.4-60.8Industrial directoriesT11.95-12.5ENInternational Journal for Simulation and Multidisciplinary Design Optimization, Vol 12, p 26 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	cutting force finite element method micro-end milling tungsten carbide von-misses stress surface roughness ti-6al-4v Industrial engineering. Management engineering T55.4-60.8 Industrial directories T11.95-12.5
spellingShingle	cutting force finite element method micro-end milling tungsten carbide von-misses stress surface roughness ti-6al-4v Industrial engineering. Management engineering T55.4-60.8 Industrial directories T11.95-12.5 Bhople Narendra Mastud Sachin Satpal Satish Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method
description	Micromilling is one of the preferable micro-manufacturing process, as it exhibits the flexibility to produce complex 3D micro-parts. The cutting forces generated in micro end milling can be attributed for tool vibration and process instability. If cutting forces are not controlled below critical limits, it may lead to catastrophic failure of tool. Cutting force has a significant role to decide the surface roughness. Therefore accurate prediction of cutting forces and selection of suitable cutting parameters mainly feed, is important while micro end milling. In present study, finite element method (FEM) based model has been developed by using ABAQUAS/Explicit 6.12 software. Von-Misses stresses and cutting forces are predicted while micro end milling of Ti-6Al-4V. Further, cutting forces were measured during experimentation using dynamometer mounted on micro-milling test bed. Cutting forces predicted by FEM model are in good agreement with the experimental force values. Obtained FEM results have been used to study the size effect in micro end milling process. Moreover, the effect of uncut chip thickness to cutting edge radius ratio (h/rc) on surface roughness (Ra) has been studied. It is found the feed 2.5 µm/tooth is suitable value to produce optimum surface roughness and cutting forces.
format	article
author	Bhople Narendra Mastud Sachin Satpal Satish
author_facet	Bhople Narendra Mastud Sachin Satpal Satish
author_sort	Bhople Narendra
title	Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method
title_short	Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method
title_full	Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method
title_fullStr	Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method
title_full_unstemmed	Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method
title_sort	modelling and analysis of cutting forces while micro end milling of ti-alloy using finite element method
publisher	EDP Sciences
publishDate	2021
url	https://doaj.org/article/d95436a46cec4f3299fb6ea1ac25a0df
work_keys_str_mv	AT bhoplenarendra modellingandanalysisofcuttingforceswhilemicroendmillingoftialloyusingfiniteelementmethod AT mastudsachin modellingandanalysisofcuttingforceswhilemicroendmillingoftialloyusingfiniteelementmethod AT satpalsatish modellingandanalysisofcuttingforceswhilemicroendmillingoftialloyusingfiniteelementmethod
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Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method

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