Analytical modeling, experimental investigations and performance test of mist coolant on micro end milling operations

Abstract

In the present day manufacturing arena, one of the most important fields of interest lies in the manufacturing of miniaturized components. End milling with fine-grained carbide micro end mills is an efficient and economical means for medium and small lot production of micro components. Analysis of the cutting force in micro end milling plays a vital role in characterizing the cutting process, in estimating the tool life and in optimizing the process. A new approach to analytical three dimensional cutting force modeling has been introduced in this study based on the theoretical chip area. The simulated values of the forces from the model are compared with experimental values and are found to be in good agreement. Following this, the tool wear mechanism in micro end milling operations is investigated and the significance of tool engagement and "size effect" in micro end milling operations are illustrated. Finally, performance of mist coolant on micro end milling operation has been studied.