Effect of Machine Structure on Cutting Force Considering Different Working Conditions in Micro-End-Milling

Abstract

Machine structure determines the performance of machine tools. The study of machine deformation contributes to the stability of machining processes, which in turn improves machining accuracy and surface quality. Vertical structure is the weak part of the horizontal micro-milling machine, which is the main source of deformation. Considering that the micro-milling cutting parameters and machine deformations are at the micron scale, it remains to be investigated whether such deformations cause changes in the cutting volume and thus affect the cutting forces. For this purpose, this paper investigates the deformation of the machine structure caused by various operating conditions and its effect on the cutting force. The finite element method (FEM) was used to calculate the deformation [Formula: see text][Formula: see text] of the clamp-workpiece. To verify the effect of machine structure on cutting force under different working conditions, the Al 6061 full immersion slot cutting experiments were conducted by considering different cutting parameters. The results show that the deformation of the machine structure has an effect on the cutting forces, and the degree of effect varies depending on the working conditions.