Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method

Micromilling is one of the preferable micro-manufacturing process, as it exhibits the flexibility to produce complex 3D micro-parts. The cutting forces generated in micro end milling can be attributed for tool vibration and process instability. If cutting forces are not controlled below critical limits, it may lead to catastrophic failure of tool. Cutting force has a significant role to decide the surface roughness. Therefore accurate prediction of cutting forces and selection of suitable cutting parameters mainly feed, is important while micro end milling. In present study, finite element method (FEM) based model has been developed by using ABAQUAS/Explicit 6.12 software. Von-Misses stresses and cutting forces are predicted while micro end milling of Ti-6Al-4V. Further, cutting forces were measured during experimentation using dynamometer mounted on micro-milling test bed. Cutting forces predicted by FEM model are in good agreement with the experimental force values. Obtained FEM results have been used to study the size effect in micro end milling process. Moreover, the effect of uncut chip thickness to cutting edge radius ratio (h/rc) on surface roughness (Ra) has been studied. It is found the feed 2.5 µm/tooth is suitable value to produce optimum surface roughness and cutting forces.