This paper presents the development of models that describe the surface-generation process for microendmilling. The surface-generation models for the sidewall and floor surfaces consist of deterministic and stochastic models. In the sidewall surface-generation model, the deterministic model characterizes the surface topography generated from the relative motion between the major cutting edge and the workpiece material. The model includes the effects of the process kinematics, dynamics, tool edge serration, and process faults (e.g., tool tip runout). The stochastic model predicts the increased surface roughness generated from ploughing due to the significant tool edge radius effect. In the floor surface-generation model, the deterministic model characterizes the three-dimensional surface topography over the entire floor surface and considers the effects of the minimum chip thickness, the elastic recovery, and the transverse vibration. The variation of the ploughing amount across the swept arc of the cutter due to the varying chip load conditions is considered in the stochastic model.
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June 2007
Technical Papers
Model-Based Analysis of the Surface Generation in Microendmilling—Part I: Model Development
Xinyu Liu,
Xinyu Liu
Graduate Research Assistant
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL
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Richard E. DeVor,
Richard E. DeVor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL
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Shiv G. Kapoor
Shiv G. Kapoor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL
Search for other works by this author on:
Xinyu Liu
Graduate Research Assistant
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL
Richard E. DeVor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, IL
Shiv G. Kapoor
Professor
Fellow ASME
Department of Mechanical and Industrial Engineering,
University of Illinois at Urbana-Champaign
, Urbana, ILJ. Manuf. Sci. Eng. Jun 2007, 129(3): 453-460 (8 pages)
Published Online: November 13, 2006
Article history
Received:
April 28, 2006
Revised:
November 13, 2006
Connected Content
A companion article has been published:
Model-Based Analysis of the Surface Generation in Microendmilling—Part II: Experimental Validation and Analysis
Citation
Liu, X., DeVor, R. E., and Kapoor, S. G. (November 13, 2006). "Model-Based Analysis of the Surface Generation in Microendmilling—Part I: Model Development." ASME. J. Manuf. Sci. Eng. June 2007; 129(3): 453–460. https://doi.org/10.1115/1.2716705
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