Modeling micro-end-milling operations. Part I: analytical cutting force model

A new analytical cutting force model is proposed for micro-end-milling operations. The model calculates the chip thickness by considering the trajectory of the tool tip while the tool rotates and moves ahead continuously. The proposed approach allows the calculation of the cutting forces to be done accurately in typical micro-end-milling operations with very aggressively selected feed per tooth to tool radius (f(t)/r) ratio. The difference of the simulated cutting forces between the proposed and conventional models can be experienced when f(t)/r is larger than 0.1. The estimated cutting force profile of the proposed model had good agreement with the experimental data. (C) 2000 Elsevier Science Ltd. All rights reserved.