Micro machining has growing number of applications in various industries such as biomedical, automotive, aerospace, micro-sensor, micro-actuator and jewelry industries. Small-sized freeform titanium parts are frequently needed in the biomedical applications, especially in the implantations such as mini-blood pumps and mini left-ventricular assist devices, finger joint replacements and small bone implants. Most of the small-sized titanium parts with freeform geometries are machined using micro ball-end milling before polishing and other surface treatments. Decreasing the cycle time of the machining parts is important for the productivity. In order to reduce the cycle time of the roughing process in the micro ball-end milling, this paper investigates the implementation of a previously developed force-based feedrate scheduling (FFS) technique on micro milling of freeform titanium parts. After briefly introducing the instantaneous micro milling forces in micro ball-end milling of titanium parts with freeform surfaces, the FFS technique is implemented in the rough machining of a freeform titanium surface to demonstrate the cycle time reduction potentials via virtual micro milling simulations.
Ali Mamedov
,
Ismail Lazoglu
. Micro ball-end milling of freeform titanium parts[J]. Advances in Manufacturing, 2015
, 3(4)
: 263
-268
.
DOI: 10.1007/s40436-015-0123-4
1. Vogler M, Kapoor S, DeVor R (2004) On the modeling and analysis of machining performance in micro-end milling—Part II: cutting force prediction. Trans ASME Journal of Manufacturing Science and Engineering 126:695-705
2. Waldorf DJ, DeVor R, Kapoor S (1998) Slip-line field for ploughing during orthogonal cutting. Trans ASME Journal of Manufacturing Science and Engineering 120:693-698
3. Jun MBG, Liu X, DeVor RE et al (2006) Investigation of the dynamics of microend milling—Part I: model development. Journal of Manufacturing Science and Engineering 128:893-900
4. Fang N (2003) Slip-line modeling of machining with a roundededge tool—Part I: new model and theory. Journal of the Mechanics and Physics of Solids 51:715-742
5. Fang N, Jawahir IS (2002) An analytical predictive model and experimental validation for machining with grooved tools incorporating the effects of strains, strain-rates and temperatures. CIRP Annals Manufacturing Technology 51:83-86
6. Jin X, Altintas Y (2011) Slip-line field model of micro-cutting process with round tool edge effect. Journal of Materials Processing Technology 211:339-355
7. Park SS, Malekian M (2009) Mechanistic modeling and accurate measurement of micro end milling forces. CIRP Annals Manufacturing Technology 58:49-52
8. Erdim H, Lazoglu I, Ozturk B (2006) Feedrate scheduling strategies for free-form surfaces. International Journal of Machine Tools and Manufacture 46:747-757
9. Ko JH, Cho DW (2004) Feed rate scheduling model considering transverse rupture strength of a tool for 3D ball-end milling. International Journal of Machine Tools and Manufacture 44:1047-1059
10. Layegh KSE, Erdim H, Lazoglu I (2012) Offline force control and feedrate scheduling for complex free form surfaces in 5-axis milling. Procedia CIRP 1:96-101
11. Yigit I, Layegh KSE, Lazoglu I (2015) A solid modeler based engagement model for 5-axis ball end milling. The 15th CIRP conference on modeling of machining operations, Karlsruhe, Germany
12. Li C, Lai X, Li H et al (2007) Modeling of three-dimensional cutting forces in micro-end-milling. Journal of Micromechanics and Microengineering 17:671-678
13. Kline W, DeVor RE (1983) The effect of runout on cutting geometry and forces in end milling. International Journal of Machine Tool Design and Research 23:123-140
14. Mamedov A, Layegh KSE, Lazoglu I (2015) Instantaneous tool deflection model for micro milling. The International Journal of Advanced Manufacturing Technology. doi:10.1007/s00170-015- 6877-9
15. Altintas Y, Kersting P, Biermann D et al (2014) Virtual process systems for part machining operations. CIRP Annals Manufacturing Technology 63:585-605
16. Budak E, Lazoglu I, Guzel BU (2004) Improving cycle time in sculptured surface machining through force modeling. CIRP Annals Manufacturing Technology 53:103-106
17. Erkorkmaz K, Layegh SE, Lazoglu I et al (2013) Feedrate optimization for freeform milling considering constraints from the feed drive system and process mechanics. CIRP Annals Manufacturing Technology 62:395-398
