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 journalJournal articleResearchpeer-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 languageEnglish
JournalProcedia CIRP
Volume82
Pages (from-to)362-367
ISSN2212-8271
DOIs
Publication statusPublished - 2019
Event17th CIRP Conference on Modelling of Machining Operations - Sheffield, United Kingdom
Duration: 13 Jun 201914 Jun 2019
Conference number: 17

Conference

Conference17th CIRP Conference on Modelling of Machining Operations
Number17
CountryUnited Kingdom
CitySheffield
Period13/06/201914/06/2019

Keywords

  • Micromilling
  • Finite Element Modelling
  • Corner Milling
  • Thinwall Machining
  • Industry 4.0

Cite this

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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",

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Optimization of corner micro end milling by finite element modelling for machining thin features. / Davoudinejad, Ali; Li, Dongya; Zhang, Yang; Tosello, Guido.

In: Procedia CIRP, Vol. 82, 2019, p. 362-367.

Research output: Contribution to journalJournal articleResearchpeer-review

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

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

VL - 82

SP - 362

EP - 367

JO - Procedia CIRP

JF - Procedia CIRP

SN - 2212-8271

ER -