Enhanced cutting force model in micro-milling incorporating material separation criterion

doi:10.1007/s40436-025-00546-z

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (4): 813-830.doi: 10.1007/s40436-025-00546-z

• • 上一篇

Enhanced cutting force model in micro-milling incorporating material separation criterion

Bo-Wen Song¹, Da-Wei Zhang¹, Xiu-Bing Jing¹, Ying-Ying Ren¹, Yun Chen², Huai-Zhong Li³

1. Key Laboratory of Equipment Design and Manufacturing Technology, School of Mechanical Engineering, Tianjin University, Tianjin, 300072, People's Republic of China;
2. Pen-Tung Sah Institute of Micro-Nano Science and Technology, Xiamen University, Xiamen, 361102, Fujian, People's Republic of China;
3. Griffith School of Engineering, Griffith University, Queensland, 4222, Australia

收稿日期:2024-03-15 修回日期:2024-05-28 发布日期:2025-12-06
通讯作者: Xiu-Bing Jing Email:E-mail:jingxiuping@tju.edu.cn;Huai-Zhong Li Email:E-mail:h.li@griffith.edu.au E-mail:jingxiuping@tju.edu.cn;h.li@griffith.edu.au
作者简介:Bo-Wen Song received the B.Eng. degree and the M.Sc. degree in Mechanical Engineering from Tianjin University. He is currently working towards the Ph.D. degree in Mechanical Engineering at School of Mechanical Engineering, Tianjin University, Tianjin, China. His current research interests include micro-scale manufacturing and vibration-assisted machining.
Da-Wei Zhang received the B.Eng. degree in Mechanical Engineering from the Shenyang University of Technology, Shenyang, China, in 1984, and the M.Sc. and Ph.D. degrees in Mechanical Engineering from Tianjin University, Tianjin, China, in 1990 and 1995, respectively. He is currently a professor with School of Mechanical Engineering, Tianjin University. He has been a visiting scholar at the Hong Kong University of Science and Technology, Clear Water Bay, Hong Kong; the University of Warwick, Coventry, U.K. and Tokyo Institute of Technology, Tokyo, Japan. His research interests include dynamics and machine tools.
Xiu-Bing Jing received her Ph.D. degree in Mechanical Engineering from Tianjin University, Tianjin, China. She is currently an associate professor in School of Mechanical Engineering at Tianjin University. Her areas of research interests include mechanical dynamics, surface engineering, micro/mesoscale manufacturing technology. She has published over 40 peer-reviewed technical papers in international journals and conference proceedings.
基金资助:
This research was supported by the Program of Tianjin Science and Technology (Grant No. 21ZXJBGX00020) and the National Natural Science Foundation of China (Grant Nos. 51875404 and 52175275).

Enhanced cutting force model in micro-milling incorporating material separation criterion

Bo-Wen Song¹, Da-Wei Zhang¹, Xiu-Bing Jing¹, Ying-Ying Ren¹, Yun Chen², Huai-Zhong Li³

1. Key Laboratory of Equipment Design and Manufacturing Technology, School of Mechanical Engineering, Tianjin University, Tianjin, 300072, People's Republic of China;
2. Pen-Tung Sah Institute of Micro-Nano Science and Technology, Xiamen University, Xiamen, 361102, Fujian, People's Republic of China;
3. Griffith School of Engineering, Griffith University, Queensland, 4222, Australia

Received:2024-03-15 Revised:2024-05-28 Published:2025-12-06
Contact: Xiu-Bing Jing Email:E-mail:jingxiuping@tju.edu.cn;Huai-Zhong Li Email:E-mail:h.li@griffith.edu.au E-mail:jingxiuping@tju.edu.cn;h.li@griffith.edu.au
Supported by:
This research was supported by the Program of Tianjin Science and Technology (Grant No. 21ZXJBGX00020) and the National Natural Science Foundation of China (Grant Nos. 51875404 and 52175275).

摘要/Abstract

摘要： Precisely discerning the material separation criterion in micro-machining remains challenging yet crucial for accurately predicting cutting forces by accounting for shearing and ploughing effects. This study introduces a novel model, the instantaneous uncut chip thickness (IUCT), to enhance the accuracy of cutting force prediction in micro-milling processes. The model quantitatively integrates instantaneous shearing thickness (IST) and instantaneous ploughing thickness (IPT). The critical determinants of shearing and ploughing effects rely on the material separation point, modeled using the dead metal zone concept, which considers chip fracture caused by incomplete material accumulation. The micro-milling process is categorized into four types based on the proportion of IST and IPT within one revolution. Mechanistic cutting-force models are developed for each type and validated through experiments. The experimental results align closely with theoretical predictions, with peak force errors remaining within 10%, affirming the accuracy of the analytical force models.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00546-z

关键词: Micro-milling, Cutting force, Material separation criterion, Shearing effect, Ploughing effect

Abstract: Precisely discerning the material separation criterion in micro-machining remains challenging yet crucial for accurately predicting cutting forces by accounting for shearing and ploughing effects. This study introduces a novel model, the instantaneous uncut chip thickness (IUCT), to enhance the accuracy of cutting force prediction in micro-milling processes. The model quantitatively integrates instantaneous shearing thickness (IST) and instantaneous ploughing thickness (IPT). The critical determinants of shearing and ploughing effects rely on the material separation point, modeled using the dead metal zone concept, which considers chip fracture caused by incomplete material accumulation. The micro-milling process is categorized into four types based on the proportion of IST and IPT within one revolution. Mechanistic cutting-force models are developed for each type and validated through experiments. The experimental results align closely with theoretical predictions, with peak force errors remaining within 10%, affirming the accuracy of the analytical force models.

The full text can be downloaded at https://doi.org/10.1007/s40436-025-00546-z

Key words: Micro-milling, Cutting force, Material separation criterion, Shearing effect, Ploughing effect

Bo-Wen Song, Da-Wei Zhang, Xiu-Bing Jing, Ying-Ying Ren, Yun Chen, Huai-Zhong Li. Enhanced cutting force model in micro-milling incorporating material separation criterion[J]. Advances in Manufacturing, 2025, 13(4): 813-830.

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Enhanced cutting force model in micro-milling incorporating material separation criterion

Enhanced cutting force model in micro-milling incorporating material separation criterion

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