Tool deflection model for micromilling processes

Research in micromilling processes has found that tool deflection phenomenon affects the forces significantly, causing a smoothing effect in the tool run-out. Therefore, this needed to be taken into account to design a model for reliably predicting the cutting forces in these processes. In this paper, a study of the tool deflection phenomenon was carried out by applying the principles of elasticity of materials to the situation of a tool under a distributed force along its edge. The contribution of this study consisted of considering a variable deflection along the length of the edge, which has not been taken into account in previous models. A new methodology of obtaining the rigidity, based on experimental data, was applied to two specific types of mills by using their geometry. With this model, a linear equations system that allows the prediction of cutting forces was obtained. These predictions, which were calculated with a low computational cost, can be used in monitoring systems and adaptive control of the process for the prevention of tool failure.