The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics

In the fabrication process of thin-walled micro-parts, both micro-cutting tools and micro-parts have characteristics small size low stiffness. Therefore, regenerative chatter during machining cannot be ignored. The influence tool runout error actual trochoidal trajectories cutting edge on micro-milling forces should also considered comprehensively. this paper, in is first analysed, an instantaneous undeformed chip thickness model established considering error. On basis, dynamic deformation micro-part studied, instantaneous, undeformed, chip-thickness proposed with consideration deformation. parameters system are obtained using receptance coupling method. Finally, experiments carried out, results force simulation based compared experimental results. indicate that modelling, by taking dynamics into account, has better prediction accuracy, difference between predicted resultant less than 11%.