Enhanced cutting force model in micro-milling incorporating material separation criterion

Bo-Wen Song; Da-Wei Zhang; Xiu-Bing Jing; Ying-Ying Ren; Yun Chen; Huai-Zhong Li

doi:10.1007/s40436-025-00546-z

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (4) :813 -830. DOI: 10.1007/s40436-025-00546-z

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Enhanced cutting force model in micro-milling incorporating material separation criterion

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¹Key Laboratory of Equipment Design and Manufacturing Technology, School of Mechanical Engineering, Tianjin University, 300072, Tianjin, People’s Republic of China

²Pen-Tung Sah Institute of Micro-Nano Science and Technology, Xiamen University, 361102, Xiamen, Fujian, People’s Republic of China

³Griffith School of Engineering, Griffith University, 4222, Queensland, Australia

jingxiuping@tju.edu.cn

h.li@griffith.edu.au

Bo-Wen Song

Bo-Wen Song received the B.Eng. degree and the M.Sc. degree in Mechanical Engineering from Tianjin University. He is currently working towards the Ph.D. degree in Mechanical Engineering at School of Mechanical Engineering, Tianjin University, Tianjin, China. His current research interests include micro-scale manufacturing and vibration-assisted machining.

Da-Wei Zhang

Da-Wei Zhang received the B.Eng. degree in Mechanical Engineering from the Shenyang University of Technology, Shenyang, China, in 1984, and the M.Sc. and Ph.D. degrees in Mechanical Engineering from Tianjin University, Tianjin, China, in 1990 and 1995, respectively. He is currently a professor with School of Mechanical Engineering, Tianjin University. He has been a visiting scholar at the Hong Kong University of Science and Technology, Clear Water Bay, Hong Kong; the University of Warwick, Coventry, U.K. and Tokyo Institute of Technology, Tokyo, Japan. His research interests include dynamics and machine tools.

Xiu-Bing Jing

Xiu-Bing Jing received her Ph.D. degree in Mechanical Engineering from Tianjin University, Tianjin, China. She is currently an associate professor in School of Mechanical Engineering at Tianjin University. Her areas of research interests include mechanical dynamics, surface engineering, micro/mesoscale manufacturing technology. She has published over 40 peer-reviewed technical papers in international journals and conference proceedings.

Ying-Ying Ren

Ying-Ying Ren is an ME candidate in Mechanical Engineering at School of Mechanical Engineering, Tianjin University. Her current research interests include micro/nano machining and micro-machine tools for manufacturing of precision parts.

Yun Chen

Yun Chen obtained a PhD degree from University of New South Wales, Australia. She is an assistant professor from Xiamen University, China. Her research areas include hybrid metallic additive and subtractive manufacturing, machining dynamics and cutting condition monitoring.

Huai-Zhong Li

Huai-Zhong Li obtained a PhD degree from National University of Singapore. He is currently a senior lecturer at School of Engineering and Built Environment, Griffith University, Australia. He is a Fellow of International Academy of Engineering and Technology (AET), Fellow of the Higher Education Academy (FHEA), and Fellow of the Griffith Learning and Teaching Academy. His research interests include advanced manufacturing technologies, micromachining, machine dynamics, vibration monitoring and control, and mechatronics.

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Abstract

Precisely discerning the material separation criterion in micro-machining remains challenging yet crucial for accurately predicting cutting forces by accounting for shearing and ploughing effects. This study introduces a novel model, the instantaneous uncut chip thickness (IUCT), to enhance the accuracy of cutting force prediction in micro-milling processes. The model quantitatively integrates instantaneous shearing thickness (IST) and instantaneous ploughing thickness (IPT). The critical determinants of shearing and ploughing effects rely on the material separation point, modeled using the dead metal zone concept, which considers chip fracture caused by incomplete material accumulation. The micro-milling process is categorized into four types based on the proportion of IST and IPT within one revolution. Mechanistic cutting-force models are developed for each type and validated through experiments. The experimental results align closely with theoretical predictions, with peak force errors remaining within 10%, affirming the accuracy of the analytical force models.

Keywords

Micro-milling / Cutting force / Material separation criterion / Shearing effect / Ploughing effect

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Bo-Wen Song, Da-Wei Zhang, Xiu-Bing Jing, Ying-Ying Ren, Yun Chen, Huai-Zhong Li. Enhanced cutting force model in micro-milling incorporating material separation criterion. Advances in Manufacturing, 2025, 13(4): 813-830 DOI:10.1007/s40436-025-00546-z

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