Model for predicting tool life in micro milling of copper

Abstract

In micro milling process, predicting the life of micro grain carbide cutter is quite tedious and cumbersome because of the size, dimension and unpredictable nature of tool failure. An empirical model is presented using a second order equation for predicting the tool life of micro end mill cutter under dry cutting condition. The model is developed covering wide ranges of primary variables such as cutting speed, feed rate and axial depth of cut by optimizing the response to maximize the tool life. The model presented is adequate for a 95% of confidence interval, and shows good correlation between experimental and predicted results.