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Characterization of tool-workpiece contact during the micromachining of conductive materials.pdf

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Characterization of tool-workpiece contact during the micromachining of conductive materials.pdf

Mechanical Systems and Signal Processing 83 (2017) 489–505 Contents lists available at ScienceDirect Mechanical Systems and Signal Processing journal homepage: /locate/ymssp Characterization of tool-workpiece contact during the micromachining of conductive materials Fernando Casta?o n, Rodolfo E. Haber, Raúl M. del Toro Centre for Automation and Robotics (UPM-CSIC), Arganda del Rey, Madrid, Spain article info Article history: Received 6 August 2015 Received in revised form 14 June 2016 Accepted 16 June 2016 Available online 30 June 2016 Keywords: Micromachining Micro-milling Tool-piece contact area modeling Spreading resistance abstract The characterization of dynamic cutting in micro-machining operations is essential for real-time monitoring of tool performance. The analysis of tool-edge/material contact and its electrical resistivity is therefore an interesting avenue of research for monitoring toolworkpiece interaction. This study examines mechanical cutting operations in micromilling operations that remove material to meet the design requirements of conductive parts. It draws from previous research into the theoretical models of cutting mechanisms in milling operations, to present a mathematical characterization of the tool-edge/material contact area. The rationale behind this research is that the contact area between two conductive materials is one of the main factors in determining the magnitude of resistance to the flow of an electric current between both materials. The study also offers a theoretical analysis of tool-edge radial immersion angles on entry and exit and their dynamic behavior. The analysis is mainly centered on cutting operations and cutting-time intervals, where tool-material contact is intermittent. Our theoretical analysis is experimentally corroborated by measuring tool-edge immersion time and tool-edge/material contact time. Promising results are reported that contribute to the development of a technological method for high-precision, real