Approach for modeling accurate undeformed chip thickness in milling operation

An accurate approach of the instantaneous undeformed chip thickness is a key issue for analyzing milling process. The presented models for approximating instantaneous undeformed chip thickness are oversimplified and complex for use in academic and manufacture practice. In this paper, a new model for determining the undeformed chip thickness in milling process with higher accuracy is proposed. According to the true trochoid path of tool tooth, the true instantaneous undeformed chip thickness can be derived by solving the deduced transcendental equation. An iterational algorithm is used to approach the value in the transcendental equation with infinitesimal calculation error. Our main contributions include that the accurate positions of the geometric points of the undeformed chip profile with different level of width of cut are analyzed and derived, as well as the accurate undeformed chip thicknesses of the chip cross-section profile are approached by iterative algorithm. Case studies with different parameter combinations show that the new model has a higher accuracy compared with the presented models. With this innovative approach, a method of accurate prediction of the geometric profile and thickness of the undeformed chip profile in milling process is provided.

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