Cutting force modeling and experimental validation for micro end milling

Abstract

Micro end milling has an outstanding capability in machining micro-scale structures of various materials. Prediction of cutting forces is significant on controlling quality and safety of machining process. This paper proposes a mechanic model to predict cutting forces in micro end milling process, which includes a novel algorithm of instant uncut chip thickness. This algorithm takes into account the geometric errors of machining system and trochoidal trajectory of cutting edge, which redefines cutting radii with consideration of the tool runout. A feasible technique to reduce the influence of tool runout is put forward by analyzing the redefined cutting radii. Since the existing method for cutting force coefficient identification is generally conducted using finite element simulation, it is difficult for some composite materials due to lack of the material properties. To overcome the above shortcomings, an experimental-based cutting force coefficient identification technique has been developed by groove milling. A number of experimental testing have been conducted to validate the developed cutting force model. Experimental results are in good agreement with theoretical predictions, which demonstrates the validity of proposed cutting force modeling.