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The effects of motion mode, rate and the distance between tool and workpiece on micromachining quality were investigated.
The relative tool-work vibration is not generalized enough to represent the actual displacement between tool and workpiece in previous prediction models.
This model consists of following subsystems, i.e. stationary model of one-side-supported flexible workpiece (modal subsystem), non-stationary discrete model of ball-end mill (structural subsystem) and conventional contact point between tool and workpiece (connective subsystem).
It is indicated that the interfacial friction coefficient between tool and workpiece is changed with the variety of the tool rotational speed, which impacts the TIF but has not been taken into account in most current TIF models.
Lubricant is essential in the conventional metal forming to reduce the friction between tool and workpiece and forming energy, to increase the forming limit, to shorten the forming process, and to prolong the tool life by prevention of galling and seizure.
During EDDM, there is no direct contact between tool and workpiece, so eliminating the tool pressure.
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At larger value of T on, larger current flows between the tool and workpiece, which increases the discharge energy between the spark gap and hence larger erosion rate finally increases grade value.
However studies on the interaction between the tool and workpiece responses in thin wall machining are scarce in the literature.
In this system, the workpiece is driven by a specially designed active stage to control the relative vibration between the tool and workpiece during milling processes.
For the correct operation of this special kind of tool, the set up for optimal distance between the tool and workpiece was introduced also taking into the account the measured rolling force (Fz), which occurs between the tool and workpiece because the magnetic force pulls the rolling balls on a cone which is located at the end of the tool.
A comprehensive model of the physical interaction between SAG tool and workpiece is proposed, and used to understand the mechanics driving brittle-ductile transition on ceramic materials such as SiC.
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