NUMERICAL STUDY OF MICRO-MILLING PROCESS USING FINITE ELEMENT METHOD

Abstract

ABSTRACT - The micro-milling process is a critical technique in manufacturing small-scale
components with high precision and accuracy. Studies have been extensively conducted to investigate
the effects of various process parameters on the performance of micro-milling process. Furthermore,
simulation studies have been widely carried out to predict cutting forces, tool wear and tool deflection
while at the same time reducing the cost of manufacturing. In this study, the effect of cutting parameters
and the capabilities of the finite element method (FEM) to analyse the cutting force and tool wear during
the micro-milling process is discussed using Abaqus software. The methodology of this study was
justified. A three-dimensional model of micro-milling process was developed and two different cutting
parameters were analysed using Abaqus software. The cutting parameters tested during the
micro-milling process were between Vc= 100 m/min, f=4 µm, d=75 µm as the lowest and Vc= 100
m/min, f=4 µm, d=75 µm as the highest, which were analysed on the 20 mm material workpiece length
of tool travel. Results demonstrated that as the cutting progressed, all cutting force components
increased significantly due to the tool wear. This simulation study will provide insights into the
optimisation of process parameters for improved productivity and part quality.