Mechanistic modeling and accurate measurement of micro end milling forces

Micro milling operations can fabricate miniaturized components with high relative accuracy. Since micro machining operations are different than conventional macro machining processes, due to the large negative rake angle and elasto-plastic effects, it is important that the modeling of micro end milling forces incorporates the dynamics of the tool, ploughing and elastic recovery. This study examines the mechanistic modeling of shearing and ploughing domain cutting regimes to accurately predict micro milling forces. The tool dynamics are indirectly identified by performing receptance coupling analysis. Furthermore, the Kalman filter compensation method is used to precisely measure the forces to obtain the cutting constants.