Modeling of dynamic micro-milling cutting forces

This paper investigates the mechanistic modeling of micro-milling forces, with consideration of the effects of ploughing, elastic recovery, run-out, and dynamics. A ploughing force model that takes the effect of elastic recovery into account is developed based on the interference volume between the tool and the workpiece. The elastic recovery is identified with experimental scratch tests using a conical indenter. The dynamics at the tool tip is indirectly identified by performing receptance coupling analysis through the mathematical coupling of the experimental dynamics with the analytical dynamics. The model is validated through micro end milling experiments for a wide range of cutting conditions.