Taylor-based model for micro-machining of single crystal fcc materials including frictional effects—Application to micro-milling process

This paper presents the application of micro-plasticity theory to predict the forces and the surface quality that stem from the anisotropy in the mechanical properties of single crystal fcc work-piece materials. The cutting orientation defined by a cutting direction and cutting plane, changes with respect to the crystal orientation of the work-piece during one revolution of the flute of an end-mill. The shear angle and the crystallographic work to pursue shearing change as the flute of the cutter rotates. The model predicts the experimental differences in the height between entrance and exit burrs of copper single crystals observed in the studies of Min et al. [Variation in machinability of single crystal materials in micromachining, Annals of CIRP (2006) 55/1]. Model is potentially applicable to calibration of milling force models.