Mechanistic modelling of the micro- end milling operation

The paper describes a mechanistic model to predict the micro--milling cutting forces and to estimate the tool deflection and the real tool-path during the micro--milling process. Beginning from the “conventional” end milling cutting force model, several modifications are proposed to adapt it for the prediction of the micro--milling cutting forces, which is tha aim of this research. A variety of end mill shapes are considered in the geometric part of the model. The paper presents the experimental validation using two-flute carbide micro-- end-mills with diameters from 0.1 to 0.4 mm. Finally, the consistency between the simulated and measured cutting force is shown as main conclusion.