Machining Forces and Tool Deflections in Micro Milling

The analysis of cutting forces plays an important role for investigation of mechanics and dynamics of cutting process. The importance of force analysis is due to its major role in surface quality of machined parts. Presented force model calculates instantaneous chip thickness by considering trajectory of the tool tip while tool rotates and moves ahead continuously. The model also takes plowing force component into consideration relating it to elastic recovery based on interference volume between tool and workpiece. Based on the mathematical model, distribution of the force acting on the tool is calculated. It is known that this force will create deflection of the tool during cutting, which will result in imperfections of the final part. From this point of view, it is important to predict tool deflections in order to control the cutting process and to avoid failure of the tool. Both force and deflection models are validated on Aerospace Aluminum Alloy (Al-7050), through micro end milling experiments for a wide range of cutting conditions using micro dynamometer and laser displacement sensors.