Empirical analysis of cutting force constants in micro-end-milling operations

The micro-end-milling operations typically have aggressive feed per tooth per radius compared to conventional milling operations thereby resulting in different forces and cutting force constants. In addition, the trochoidal nature of the tool path could also result in different force constants. An empirical model for the analysis of cutting forces in micro-end-milling operations is presented. The approach uses higher feed per tooth per radius of cutter ratios (compared to conventional end-milling operations) and the true trochoidial nature of the tool edge path in the derivation of a chip thickness for micro-end-milling operations. Cutting experiments were conducted in the micro-end-milling regime and forces were recorded. These forces were then decomposed in order to present new empirical formulae for cutting pressure constants in micro-end-milling operations. The model developed for cutting force constants will aid in better understanding of friction and forces in the micro-end-milling process.