Finite element simulation of high speed micro milling in the presence of tool run-out with experimental validations

Micro milling process of CuZn37 brass is considered important due to applications in tool production for micro moulding and
micro replication technology. The variations in material properties, work material adhesion to tool surfaces, burr formation, and
tool wear result in loss of productivity. The deformed chip shapes together with localized temperature, plastic strain, and cutting
forces during micro milling process can be predicted using finite element (FE) modeling and simulation. However, toolworkpiece
engagement suffers from tool run-out affecting process performance in surface generation. This work provides
experimental investigations on effects of tool run-out as well as process insight obtained from simulation of chip flow, with
and without considering tool run-out. Scanning electron microscope (SEM) observation of the 3D chip shapes demonstrates
ductile deformed surfaces together with localized serration behavior. FE simulations are utilized to investigate the effects of micro
milling operation, cutting speed, and feed rate on forces, chip flow, and shapes. Predicted cutting forces and chip flow results
from simulations are compared with force measurements, tool run-out, and chip morphology revealing reasonable agreements.