Study of the cutting forces on micromilling of an aluminum alloy

Abstract

Micro-end-milling is one of the manufacturing processes that produce micro topography using mechanical removal, and its force modeling presents some peculiarities compared with macro-scale process. However, a few studies have been carried out using aluminum alloys and there is a lack of experimental data concerning the specific cutting force. This article applies a mechanistic cutting force model adapted for micromilling process of an aluminum alloy considering homogeneous grain properties and no tool deflection. The experiments consider different feed rates and cutting velocities, analyzing the experimental cutting force. The model uses calibration method based on experimental data used to calculate specific force and it is validated inside the cutting parameters range. Cutting speed presented more influence than feed per tooth on the specific force confirmed by the mechanistic model. The specific cutting force prediction can be used for future experiments due to good prediction and errors below 15%.