Characterization of machine tools and measurement system for micromilling

Abstract Technological progress has led to increased demand for small components with tiny features, which cannot be achieved through conventional machining. Industrial application of processes based on microcutting is limited by some issues concerning the geometrical scale. The process performance is significantly affected by milling machine, tool holder, tool, workpiece material microstructure, workpiece fixtures, and process parameters. At present, an ultimate micromachining assessment procedure is not available. This study aims to propose and conduct an experiment on a testing procedure for micromilling. The set up to be implemented and the output to be considered are defined and described. Three major stages are identified: estimation of the effective bandwidth of the load cell–tool holder system, the milling machine natural frequency measurement, and micromilling test execution. The entire procedure is performed, and its robustness is demonstrated.

[1]  Yusuf Altintas,et al.  Mechanics of micro-milling with round edge tools , 2011 .

[2]  João Paulo Davim,et al.  State of the Art on Micromilling of Materials, a Review , 2012 .

[3]  David J. Ewins,et al.  Application of MAC in the frequency domain , 2000 .

[4]  Jun Ni,et al.  Dynamic Analysis of a Mesoscale Machine Tool , 2006 .

[5]  Aldo Attanasio,et al.  Tool Run-Out Measurement in Micro Milling , 2017, Micromachines.

[6]  Pascal Ray,et al.  Modal identification of spindle-tool unit in high-speed machining , 2011 .

[7]  Tuğrul Özel,et al.  3-D finite element process simulation of micro-end milling Ti-6Al-4V titanium alloy: Experimental validations on chip flow and tool wear , 2015 .

[8]  T. Özel,et al.  Finite element simulation of high speed micro milling in the presence of tool run-out with experimental validations , 2018, The International Journal of Advanced Manufacturing Technology.

[9]  S. Smith,et al.  High Performance Milling Torque Sensor , 1998 .

[10]  Victor Songmene,et al.  Estimation of machine-tool dynamic parameters during machining operation through operational modal analysis , 2009 .

[11]  Eckart Uhlmann,et al.  Influence of the machine structure on micro milling process , 2009 .

[12]  Tuğrul Özel,et al.  Meso/micro scale milling for micro-manufacturing , 2008 .

[13]  Yusuf Altintas,et al.  Dynamic Compensation of Spindle Integrated Force Sensors With Kalman Filter , 2004 .

[14]  Sangkee Min,et al.  Recent Advances in Mechanical Micromachining , 2006 .

[15]  Yusuf Altintas,et al.  Prediction of frequency response function (FRF) of asymmetric tools from the analytical coupling of spindle and beam models of holder and tool , 2015 .

[16]  Simon S. Park,et al.  Mechanistic modeling and accurate measurement of micro end milling forces , 2009 .

[17]  Takahisa Masuzawa,et al.  State of the Art of Micromachining , 2000 .