Prediction of cutting force in micro-end-milling by a combination of analytical and FEM method

Abstract Mechanical micro-machining, in general, and micro-end-milling, in particular, has become a very good technique for fabricating 3D micro-features in a variety of materials. To optimize and control the process, prediction of the cutting force accurately is very important. In this work, a force prediction model is developed by a combination of analytical method and finite element (FE) simulations. The model predicts the cutting force components for micro-end-milling process successfully which is compared with experimental force signal obtained by using Al2024-T3 and AISI 4340 as workpiece materials. The predicted and experimental cutting forces are in very good agreement for both the amplitude and trend of the cutting force. The percentage deviation of the predicted force from the experimental force values for both feed force (Fx) and transverse force (Fy) is around 15% (except one case) for Al2024-T3. For the AISI 4340 material, the percentage deviation for Fx is around 25% and for Fy is approximately 10%. The methodology followed here is general in nature and it can be applied to any other machining process as well.