Optimization of corner micro end milling by finite element modelling for machining thin features

Ali Davoudinejad; Dongya Li; Yang Zhang; Guido Tosello

doi:10.1016/j.procir.2019.04.158

Optimization of corner micro end milling by finite element modelling for machining thin features

Ali Davoudinejad^*, Dongya Li, Yang Zhang, Guido Tosello

^*Corresponding author for this work

Research output: Contribution to journal › Journal article › Research › peer-review

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Abstract

Manufacturing thin metal features at miniature scale with high precision milling represents some challenges for different applications such as micro moulds, micro channels, micro gears, surgical instruments, etc. In order to enhance the cutting mechanism understanding and optimize the machining of thin features, 3D finite element modeling (FEM) is applied for the micro end-milling process of thin features. In this study, FE model was used to investigate the minimum wall thickness machinable in order to optimize the experimental machining and enhance the quality of the machined features. Wall thickness uniformity and burr formation were evaluated to achieve the finest overall feature quality. Finally, the FEM prediction results were compared against the experimental tests.

Original language	English
Journal	Procedia CIRP
Volume	82
Pages (from-to)	362-367
ISSN	2212-8271
DOIs	https://doi.org/10.1016/j.procir.2019.04.158
Publication status	Published - 2019
Event	17th CIRP Conference on Modelling of Machining Operations - Sheffield, United Kingdom Duration: 13 Jun 2019 → 14 Jun 2019 Conference number: 17

Conference

Conference	17th CIRP Conference on Modelling of Machining Operations
Number	17
Country/Territory	United Kingdom
City	Sheffield
Period	13/06/2019 → 14/06/2019

Keywords

Micromilling
Finite Element Modelling
Corner Milling
Thinwall Machining
Industry 4.0

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title = "Optimization of corner micro end milling by finite element modelling for machining thin features",

abstract = "Manufacturing thin metal features at miniature scale with high precision milling represents some challenges for different applications such as micro moulds, micro channels, micro gears, surgical instruments, etc. In order to enhance the cutting mechanism understanding and optimize the machining of thin features, 3D finite element modeling (FEM) is applied for the micro end-milling process of thin features. In this study, FE model was used to investigate the minimum wall thickness machinable in order to optimize the experimental machining and enhance the quality of the machined features. Wall thickness uniformity and burr formation were evaluated to achieve the finest overall feature quality. Finally, the FEM prediction results were compared against the experimental tests.",

keywords = "Micromilling, Finite Element Modelling, Corner Milling, Thinwall Machining, Industry 4.0",

author = "Ali Davoudinejad and Dongya Li and Yang Zhang and Guido Tosello",

year = "2019",

doi = "10.1016/j.procir.2019.04.158",

language = "English",

volume = "82",

pages = "362--367",

journal = "Procedia CIRP",

issn = "2212-8271",

publisher = "Elsevier",

note = "17th CIRP Conference on Modelling of Machining Operations, CIRP CMMO ; Conference date: 13-06-2019 Through 14-06-2019",

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TY - JOUR

T1 - Optimization of corner micro end milling by finite element modelling for machining thin features

AU - Davoudinejad, Ali

AU - Li, Dongya

AU - Zhang, Yang

AU - Tosello, Guido

N1 - Conference code: 17

PY - 2019

Y1 - 2019

N2 - Manufacturing thin metal features at miniature scale with high precision milling represents some challenges for different applications such as micro moulds, micro channels, micro gears, surgical instruments, etc. In order to enhance the cutting mechanism understanding and optimize the machining of thin features, 3D finite element modeling (FEM) is applied for the micro end-milling process of thin features. In this study, FE model was used to investigate the minimum wall thickness machinable in order to optimize the experimental machining and enhance the quality of the machined features. Wall thickness uniformity and burr formation were evaluated to achieve the finest overall feature quality. Finally, the FEM prediction results were compared against the experimental tests.

AB - Manufacturing thin metal features at miniature scale with high precision milling represents some challenges for different applications such as micro moulds, micro channels, micro gears, surgical instruments, etc. In order to enhance the cutting mechanism understanding and optimize the machining of thin features, 3D finite element modeling (FEM) is applied for the micro end-milling process of thin features. In this study, FE model was used to investigate the minimum wall thickness machinable in order to optimize the experimental machining and enhance the quality of the machined features. Wall thickness uniformity and burr formation were evaluated to achieve the finest overall feature quality. Finally, the FEM prediction results were compared against the experimental tests.

KW - Micromilling

KW - Finite Element Modelling

KW - Corner Milling

KW - Thinwall Machining

KW - Industry 4.0

U2 - 10.1016/j.procir.2019.04.158

DO - 10.1016/j.procir.2019.04.158

M3 - Journal article

SN - 2212-8271

VL - 82

SP - 362

EP - 367

JO - Procedia CIRP

JF - Procedia CIRP

T2 - 17th CIRP Conference on Modelling of Machining Operations

Y2 - 13 June 2019 through 14 June 2019

ER -

Optimization of corner micro end milling by finite element modelling for machining thin features

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