An experimental investigation on the machining characteristics of microscale end milling

This paper discusses an experimental approach to assess the machining characteristics in microscale end milling operation through a systematic experimentation procedure. Microchannels were machined on brass plates using a carbide end mill of 1 mm diameter to analyze the effect of chip load (feed per tooth) and cutting speed on the surface roughness, specific cutting pressure, and cutting forces during microend milling operation. The tangential and radial components of forces were analyzed with the help of a three-dimensional model using the force signals acquired through KISTLER dynamometer. Feed per tooth and the interaction of cutting speed and chip load were identified as the critical parameters affecting the surface roughness of microchannel. Applying the concept of elastic recovery on the side wall surface of microchannels, the minimum chip thickness during the above micromilling operation was evaluated as 0.97 mu m, and the result was validated by the drastic increase in specific cutting pressure and erratic behavior of cutting forces below a chip load of 1 mu m.