Rotational dynamics of micro-scale cutting tools

Bediz, Bekir and Özdoğanlar, O. Burak (2019) Rotational dynamics of micro-scale cutting tools. Precision Engineering, 60 . pp. 1-11. ISSN 0141-6359 (Print) 1873-2372 (Online)

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The dynamics of micro-scale cutting tools used during micromachining is critical to attainable process precision. Forced and self-excited vibration behavior of a micromachining process depend critically on the dynamic response of the microtools. As these micro tools are rotated at very high speeds (40,000 to 250,000 rpm) the rotational effects can play a critical role in their dynamic response. However, their the complex, multi-dimensional, and pre-twisted geometry causes a coupled dynamic response, thereby rendering the prevailing simplified one-dimensional (1D) modeling approaches inaccurate. Towards addressing this modeling challenge, in this work, we present an application of spectral-Tchebychev (ST) method to predict the three-dimensional (3D) coupled dynamics of microtools including the rotational (gyroscopic) effects. To capture the dynamics of the sectioned geometry of microtools efficiently, a unified modeling approach is followed in the modeling, merging 1D-ST models for the sections having circular cross sections, and 3D-ST models for the fluted section, which exhibits coupled three-dimensional motions due to the complex geometry. The presented solution technique is applied to predict and understand the dynamics of rotating micro-endmills and micro-drills. Natural frequencies, mode shapes, and the frequency response functions (FRFs) obtained from the unified 1D/3D-ST model are shown to have an excellent agreement with those from a commercial finite element (FE) software. The unified 1D/3D-ST model is then used to analyze the accuracy and limitations of reduced-order modeling approaches that could be used to model the rotational dynamics of microtools. Finally, the effect of rotational speed on radial throw arising from the rotational dynamics is investigated.
Item Type: Article
Uncontrolled Keywords: Micromachining dynamics; Rotating tools; Micromilling; Tool-tip dynamics; Chebyshev; Tchebychev; Spectral methods
Subjects: T Technology > TJ Mechanical engineering and machinery > TJ170-179 Mechanics applied to machinery. Dynamics
Divisions: Faculty of Engineering and Natural Sciences > Academic programs > Mechatronics
Faculty of Engineering and Natural Sciences
Depositing User: Bekir Bediz
Date Deposited: 25 Feb 2020 11:40
Last Modified: 24 Jul 2023 22:11

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