Title: Modelling and simulation of the dynamic cutting process and surface topography generation in nano/micro cutting

Authors: Lei Zhou, Kai Cheng

Addresses: School of Engineering and Design, Brunel University, Uxbridge, UB8 3PH, UK; School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China. ' School of Engineering and Design, Brunel University, Uxbridge, UB8 3PH, UK

Abstract: In nano/micro cutting process, the surface quality is heavily dependent on all the dynamic factors in machining including those from the material, tooling, cutting parameters, servo accuracy, mechanical structure deformation and non-linear factors as well. The machined surfaces are generated based on the tool profile and the real tool path combining with the various external and internal disturbances. To bridge the gap between the machining conditions and the surface quality, the integrated simulation system presented involves the dynamic cutting process, control/drive system and surface generation module. It takes into account all the intricate aspects of the cutting process, such as material heterogeneity, regenerative chatter, built-up edge (BUE), spindle run-out, environmental vibration and tool interference, etc. The frequency ratio method is used to interpret the surface topography and texture formation. The proposed systematic modelling approach is verified by the cutting experiment.

Keywords: dynamic cutting force; nonlinear factors; surface topography; tool interference; modelling; simulation; nanocutting; microcutting; nanomanufacturing; micromachining; surface quality; tool profile; tool paths; texture formation; surface roughness; nanotechnology.

DOI: 10.1504/IJNM.2009.027047

International Journal of Nanomanufacturing, 2009 Vol.3 No.1/2, pp.3 - 14

Published online: 13 Jul 2009 *

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