Mechanics of micro-milling with round edge tools

This paper presents analytical prediction of micro-milling forces from constitutive model of the material and friction coefficient. The chip formation process is predicted with a slip-line field model which considers the strain hardening, strain-rate and temperature effects on the flow stress of the material. The cutting force coefficients are identified from series of slip-line field simulations at a range of cutting edge radii and chip loads. The predicted cutting force coefficients are used to simulate micro-milling forces. The proposed chain of predictive micro-milling model is experimentally proven by conducting brass cutting tests with a 200 mu m diameter helical end mill. (C) 2011 CIRP.