Richard E. DeVor

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In Part II of this paper, a cutting force model for the micro-endmilling process is developed. This model incorporates the minimum chip thickness concept in order to predict the effects of the cutter edge radius on the cutting forces. A new chip thickness computation algorithm is developed to include the minimum chip thickness effect. A slip-line plasticity(More)
A mechanistic model for the micro-endmilling process is developed that explicitly accounts for the different phases while machining heterogeneous materials. It is shown that frequencies in the cutting force signal higher than those that can be explained by the kinematics of the process can be explained by considering the multiple phases in the material.(More)
This paper provides a comprehensive review of the literature, mostly of the last 10–15 years, that is enhancing our understanding of the mechanics of the rapidly growing field of micromachining. The paper focuses on the mechanics of the process, discussing both experimental and modeling studies, and includes some work that, while not directly focused on(More)
This paper presents an evaluation of a spindle-based force sensor, the force ring, which is a strong candidate for in-process monitoring and fault diagnosis of machining operations. The evaluation criteria include the effect of integration of the force ring on the dynamics of the spindle, the drift behavior due to temperature change inside the spindle, the(More)
A dynamic cutting force and vibration model of the microendmilling process that accounts for the dynamics of the microendmill, influences of the stable built-up-edge, and the effects of minimum chip thickness, elastic recovery, and the elastic-plastic nature in ploughing/rubbing has been developed. Experimental validation has been performed, and the model(More)
Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces.(More)
A s t r a t e g y i s d e v e l o p e d f o r i d e n t i f y i n g c u t t i n g t o o l w e a r o n a f a c e m i l l b y a u t o m a t i c a l l y r e c o g n i z i n g w e a r p a t t e r n s i n t h e c u t t i n g f o r c e s i g n a l . T h e s t r a t e g y u s e s a m e c h a n i s t i c m o d e l d e v e l o p m e n t t o p r e d i c t f o r c e s(More)
An automated microfactory is developed and demonstrated for multi-operation manufacturing of micro/meso-scale components. In this first paper of a two-part series, a flexible microfactory architecture is developed that supports automated operation. Improved microfactory machines, including a three-axis micro/mesoscale machine tool (mMT), a five-axis mMT and(More)