Modelling and analysis of cutting forces while micro end milling of Ti-alloy using finite element method

Micromilling is one of the preferable micro-manufacturing process, as it exhibits flexibility to produce complex 3D micro-parts. The cutting forces generated in micro end milling can be attributed for tool vibration and process instability. If are not controlled below critical limits, may lead catastrophic failure tool. Cutting force has a significant role decide surface roughness. Therefore accurate prediction selection suitable parameters mainly feed, important while milling. In present study, finite element method (FEM) based model been developed by using ABAQUAS/Explicit 6.12 software. Von-Misses stresses predicted Ti-6Al-4V. Further, were measured during experimentation dynamometer mounted on micro-milling test bed. FEM good agreement with experimental values. Obtained results have used study size effect process. Moreover, uncut chip thickness edge radius ratio ( h/rc ) roughness (Ra) studied. It found feed 2.5 µm/tooth value optimum forces.