Prediction of Cutting Forces in Micro Milling of p-20 Steel by TiAln coated wc tool: An Analytical Approach

Fig. 1 (ab Top face of micro end mill, (b)

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Fig. 1 (ab Top face of micro end mill, (b) Enlarged view of the edge The aforesaid literature survey unveils the effect of coating in micro milling and the necessity of analytical model. However, all the analytical cutting force models for micro milling reported in literature are valid for uncoated carbide tool and these may notwork properly for coated tool as properties of the tool changes from substrate material due to coating. Furthermost of the models extract the cutting coefficients from cutting calibration experiment which are also not cost effective. Again, few literatures are available those extracted the cutting coefficient from FEM simulation
Therefore, by considering the aforementioned scopes and to bridge such gap, the current study proposes an analytical model for the prediction of cutting forces in micro

4 milling for TiAlN coated tool. The analytical model has been established by extracting the force coefficients from thermo-mechanical based FEM simulation. The cutting coefficients obtained by FEM have been used in mechanistic model by aggregating the effects of tool run out, minimum chip thickness and elastic recovery. Finally, the adequacy of the proposed model has been taken care by validating it with experimental data.

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