Surface generation modelling for micro end milling considering the minimum chip thickness and tool runout

Surface roughness is considered as one of the significant factors on the quality and functionality of micro components. Considering that in micro milling feed per tooth and uncut chip thickness are very small compared to those in conventional milling, it is necessary to study surface generation precisely in micro scale. This paper proposes a surface generation model for micro-end-milling process, where the effect of the minimum chip thickness (MCT) and tool runout are considered. The MCT values were determined through finite element simulations for AISI 1045 steel, and the magnitudes of the tool runout in machining rotational speed was obtained by displacement measurement using capacitive sensors. Based on the proposed model, the influence of the tool runout, MCT as well as the tool geometric parameters on the surface generation was studied. Finally, simulation results were compared with experimental data and a good agreement was obtained