Abstract
Abstract Predictive models that are developed based on the assumption of perfectly sharp cutting tools yield reasonable accurate results for conventional machining. But the same assumption is not valid for micromachining as the undeformed chip thickness a in microscale approaches the tool edge radius r of several microns. In this study, finite element analysis (FEA) of micromachining using the arbitrary Lagrangian–Eulerian (ALE) method showed that chip is formed through material extrusion under a critical a/r
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