Title: Mechanistic modelling of dynamic cutting forces in micro end milling of Zr-based bulk metallic glass

Authors: Debajyoti Ray; Asit Baran Puri; Naga Hanumaiah; Saurav Halder

Addresses: Department of Mechanical Engineering, National Institute of Technology Durgapur, Durgapur 713209, West Bengal, India ' Department of Mechanical Engineering, National Institute of Technology Durgapur, Durgapur 713209, West Bengal, India ' Central Manufacturing Technology Institute (CMTI), Bengaluru 560022, Karnataka, India ' CSIR-Central Mechanical Engineering Research Institute (CMERI), Durgapur 713209, West Bengal, India

Abstract: This paper presents the mechanistic modelling of dynamic cutting forces in micro end milling using cutting force coefficients determined empirically from the average cutting forces in the ploughing and shearing dominant regimes. The influence of the cutting tool edge radius and the effects of ploughing, elastic recovery, overlapping tooth engagement of the cutting tool etc. are considered in the cutting force model. The ploughing forces are modelled as proportional to the interactive area between the rounded cutting edge and the work material. The proposed model is compared with the results of several micro milling experiments with Zr-based bulk metallic glass. The study reveals that the radial ploughing coefficient is larger than the tangential ploughing coefficient. However, the tangential cutting coefficient is found to be larger than the radial cutting coefficient. The developed model is found to predict the cutting forces fairly well under different micro cutting conditions.

Keywords: micro end milling; cutting forces; mechanistic model; cutting force coefficients; cutting edge radius; ploughing; elastic recovery; bulk metallic glass.

DOI: 10.1504/IJMMM.2020.111356

International Journal of Machining and Machinability of Materials, 2020 Vol.22 No.6, pp.527 - 550

Received: 09 Sep 2019
Accepted: 30 Jan 2020
Published online: 23 Nov 2020 *

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