Two-dimensional vibration-assisted micro end milling: Cutting force modelling and machining process dynamics

Abstract

A three-dimensional (3D) cutting force model of two-dimensional (2D) vibration-assisted micro end milling (2D VAMEM) is presented in this paper. The model calculates the chip thickness by considering the relative trajectory of the tool tip to the workpiece while the tool rotates and the workpiece moves ahead continuously and vibrates in the feed and normal directions. In addition, a cutting process dynamics model of 2D VAMEM is established, which is combined with the cutting force model. The estimated cutting forces using the proposed models with and without considering dynamics both have a reasonable agreement with the experimental while considering dynamics leads to close agreement with the experimental data. The effects of amplitude on the maximum cutting force level and average cutting force are also studied. The two proposed models can be used to study the various characteristics of 2D VAMEM, including dynamic stability, positioning accuracy, surface texture generation, and tool wear.