Improved Cutting Force Modelling in Micro-Milling Aluminum Alloy LF 21 Considering Tool Wear
Source abstract
Abstract
Aluminum alloy LF 21 has a strong ability to reflect electromagnetic waves. LF 21 waveguide slit array structure is widely used in waveguide radar antenna. The stiffness of the slit array structure is relatively weak. So, the structure is prone to deformation under the cutting force in the conventional milling process. Micro-milling technology can realize high-precision machining of mesoscale parts/structures and is a potential effective machining technology for the waveguide slit array structure. However, the diameter of the micro-milling cutter is small, and the feed per tooth is comparable to the arc radius of the cutting edge, so the micro-milling cutter is prone to wear. In addition, the effects of elastic recovery of material, the minimum cutting thickness and friction of cutting dead zone on micro-milling force cannot be ignored. A simulation model of micro-milling aluminum alloy LF 21 processes based on DEFORM 3D is built by combining the theory of cutting and the technology of process simulation. Prediction of tool wear is achieved. The quantitative relationship between the arc radius of the cutting edge and tool wear is clarified for the first time. The authors built an improved cutting force model in micro-milling LF 21 considering tool wear and cutter runout with the minimum cutting thickness as the boundary. The validity of the built micro-milling force model is verified by experiments.
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Research context
OpenAlex topics: Advanced machining processes and optimization · Advanced Surface Polishing Techniques · Advanced Machining and Optimization Techniques
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, No.2 Linggong Road, Dalian 116026, China
Department of Electronic Information and Electrical Engineering, Dalian University of Technology, Dalian 116026, China
The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332-0405, USA
Funding
National Natural Science Foundation of China · Fundamental Research Funds for the Central Universities · DalianScience and Technology Innovation Fund
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