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Mechanics and dynamics of micro-cutting process

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dc.contributor.author Jin, Xiaoliang
dc.date.accessioned 2012-09-28T16:51:11Z
dc.date.available 2012-09-28T16:51:11Z
dc.date.copyright 2012 en
dc.date.issued 2012-09-28
dc.identifier.uri http://hdl.handle.net/2429/43289
dc.description.abstract Micro-cutting operations are used to manufacture miniature parts in biomedical, optics, electronics, and sensors industry. Compared to chemical manufacturing processes, micro-cutting has the advantage of producing three-dimensional features with a broad range of materials. Tool geometries and cutting conditions need to be properly selected to achieve desired surface finish and avoid premature wear or breakage of the fragile micro-tools. The mechanics and dynamics of micro-cutting have to be modeled in order to predict the process behavior and plan the operations ahead of costly physical trials. The chip thickness is comparable to the tool edge radius in micro-cutting, which brings strong size effect to the prediction of cutting force. A generalized analytical model based on slip-line field theory is proposed to predict the stress distribution and cutting force with round tool edge effect. Plastic deformation of workpiece material is modeled considering strain hardening, strain-rate and temperature effects on the flow stress. A numerical model is developed to simulate chip formation and cutting force using finite element method. The simulation results obtained from the numerical and analytical models are compared against experimental measurements to evaluate their predictive accuracy. The cutting force coefficients are modeled as functions of tool edge radius and uncut chip thickness from a series of slip-line field and finite element simulations. The identified cutting force coefficients are used to simulate micro-milling forces considering the actual tool trajectory, radial tool run-out and the dynamometer dynamics. Micro-milling forces which have sub-Newton amplitude are predicted directly from material constitutive model with experimental proof. A specially devised piezo-actuator mechanism is developed to identify the frequency response function of the micro-mill up to 120 kHz. The process damping coefficient in the ploughing region is identified from the finite element simulations. Dynamic micro-milling force with the velocity dependent process damping mechanism is modeled, and the chatter stability is predicted in frequency domain. Chatter tests are conducted to experimentally validate the dynamic model of micro-milling. The proposed mechanics and dynamic models can be used to simulate micro-cutting operations with various workpiece materials and tool geometries, and provide guidance for micro-cutting planners to select optimum cutting conditions. en
dc.language.iso eng en
dc.publisher University of British Columbia en
dc.relation.ispartof Electronic Theses and Dissertations (ETDs) 2008+ en
dc.rights Attribution-NonCommercial 2.5 Canada
dc.rights.uri http://creativecommons.org/licenses/by/3.0/
dc.title Mechanics and dynamics of micro-cutting process en
dc.type Text en
dc.degree.name Doctor of Philosophy - PhD en
dc.degree.discipline Mechanical Engineering en
dc.degree.grantor University of British Columbia en
dc.date.graduation 2012-11 en
dc.type.text Thesis/Dissertation en
dc.description.affiliation Applied Science, Faculty of
dc.degree.campus UBCV en
dc.description.scholarlevel Graduate en

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Attribution-NonCommercial 2.5 Canada Except where otherwise noted, this item's license is described as Attribution-NonCommercial 2.5 Canada

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