Cutting Force-Vibration Interactions in Precise-and Micromilling Processes: A Critical Review on Prediction Methods

Area of Science:

• Manufacturing Engineering
• Mechanical Engineering
• Materials Science

Background:

• Precise and micromilling processes are crucial in modern manufacturing.
• Existing literature lacks a consolidated review of cutting force-tool displacement interactions.
• Understanding these interactions is key to improving machining accuracy and efficiency.

Purpose of the Study:

• To provide a critical literature review on the state-of-the-art prediction methods for cutting forces and machining system displacements/vibrations in precise and micromilling.
• To identify research gaps and current trends in the field.

Main Methods:

• Review and synthesis of existing literature on cutting force and displacement models in milling.
• Analysis of the relationship between geometric cutting parameters, cutting forces, and tool displacements.
• Discussion of generalized analytical models for predicting forces and vibrations.

Main Results:

• Presentation of current cutting force, static, and dynamic displacement models applicable to precise and micromilling.
• Discussion of the interplay between cut geometry, forces, and displacements based on recent studies.
• Formulation of generalized analytical models for predicting cutting forces and vibrations.

Conclusions:

• The review highlights the need for comprehensive models predicting cutting forces and tool displacements in precise and micromilling.
• Identifies current trends and provides an outlook on future research directions in machining mechanics.
• This work serves as a synthetic resource for understanding the mechanics of precise milling and micromilling.