Finite Element Method Based Modeling for Prediction of Cutting Forces in Micro-end Milling

Abstract

Micro-end milling is one of the widely used processes for producing micro features/components in micro-fluidic systems, biomedical applications, aerospace applications, electronics and many more fields. However in these applications, the forces generated in the micro-end milling process can cause tool vibration, process instability and even cause tool breakage if not minimized. Therefore, an accurate prediction of cutting forces in micro-end milling is essential. In this work, a finite element method based model is developed using ABAQUS/Explicit 6.12 software for prediction of cutting forces in micro-end milling with due consideration of tool edge radius effect, thermo-mechanical properties and failure parameters of the workpiece material including friction behaviour at tool-chip interface. Experiments have been performed for manufacturing of microchannels on copper plate using 500 µm diameter tungsten carbide micro-end mill and cutting forces are acquired through a dynamometer. Predicted cutting forces in feed and cross feed directions are compared with experimental results and are found to be in good agreements. Results also show that FEM based simulations can be applied to analyze size effects of specific cutting forces in micro-end milling process.