Analysis of cutting force and vibration at micro-milling of a hardened steel
Barnabás Zoltán Balázs, Norbert Geier, Csongor Pereszlai, Dániel István Poór, Márton Takács
Abstract
Micro-milling is a commonly used manufacturing method; however, it is a difficult-to-design process mainly due to the size effect. The main aim of this research is the analysis of the cutting forces, the vibrations, and the dominant frequencies of the micro-milling process in a hardened steel. Full factorial machining experiments were conducted using an AlTiN coated micro end mill. The cutting forces and vibrations were analysed and discussed in detail based on material removal mechanisms, tool deflections, and dynamical behaviours. Moreover, a novel cutting force model was developed, which is adequately able to predict and optimise the cutting force.