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Micromachines 2017, 8(6), 187; doi:10.3390/mi8060187

3D Finite Element Simulation of Micro End-Milling by Considering the Effect of Tool Run-Out

1
Department of Mechanical Engineering, Technical University of Denmark, Building 427A, Produktionstorvet, 2800 Kgs. Lyngby, Denmark
2
Mechanical Engineering Department, Politecnico di Milano, Via La Masa 1, 20156 Milan, Italy
*
Author to whom correspondence should be addressed.
Academic Editor: Stefan Dimov
Received: 26 April 2017 / Revised: 6 June 2017 / Accepted: 12 June 2017 / Published: 16 June 2017
(This article belongs to the Special Issue Micro/Nano Manufacturing)
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Abstract

Understanding the micro milling phenomena involved in the process is critical and difficult through physical experiments. This study presents a 3D finite element modeling (3D FEM) approach for the micro end-milling process on Al6082-T6. The proposed model employs a Lagrangian explicit finite element formulation to perform coupled thermo-mechanical transient analyses. FE simulations were performed at different cutting conditions to obtain realistic numerical predictions of chip formation, temperature distribution, and cutting forces by considering the effect of tool run-out in the model. The radial run-out is a significant issue in micro milling processes and influences the cutting stability due to chip load and force variations. The Johnson–Cook (JC) material constitutive model was applied and its constants were determined by an inverse method based on the experimental cutting forces acquired during the micro end-milling tests. The FE model prediction capability was validated by comparing the numerical model results with experimental tests. The maximum tool temperature was predicted in a different angular position of the cutter which is difficult or impossible to obtain in experiments. The predicted results of the model, involving the run-out influence, showed a good correlation with experimental chip formation and the signal shape of cutting forces. View Full-Text
Keywords: micro milling; finite element; run-out; chip formation; cutting force; cutting temperature; 3D simulation; measurement micro milling; finite element; run-out; chip formation; cutting force; cutting temperature; 3D simulation; measurement
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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Davoudinejad, A.; Tosello, G.; Parenti, P.; Annoni, M. 3D Finite Element Simulation of Micro End-Milling by Considering the Effect of Tool Run-Out. Micromachines 2017, 8, 187.

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