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Indexed by:Journal Papers

Date of Publication:2018-05-01

Journal:Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

Included Journals:SCI、EI

Key Words:Micro-milling; cutting force; cutting temperature; coupled analysis; thermal-mechanical

Abstract:Micro-milling forces, cutting temperature, and thermal-mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal-mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal-mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier's law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal-mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.