Journal of Materials Processing Technology 213 (2013) 671–684

Contents lists available at SciVerse ScienceDirect

Journal of Materials Processing Technology

journal homepage: www.elsevier.com/locate/jmatprotec

Effects of micro-milling conditions on the cutting forces and process stability

S.M. Afazov ∗ , D. Zdebski, S.M. Ratchev, J. Segal, S. Liu
Manufacturing Research Division, University of Nottingham, Nottingham NG7 2RD, UK

a r t i c l e i n f o a b s t r a c t

Article history: Determining stable cutting conditions for corresponding cutting tools with specific geometries is essential
Received 26 June 2012 for achieving precision micro-milling with high surface quality. Therefore, this paper investigates the
Received in revised form influence of the tool rake angle, tool wear and workpiece preheating on the cutting forces and process
30 November 2012
stability. An advanced micro-milling cutting force model considering the tool wear is proposed. The
Accepted 3 December 2012
micro-milling cutting forces are predicted and compared with experimentally obtained results for two
Available online 20 December 2012
cutting conditions and four edge radii measured at different stages of the tool wear. It is found that the
cutting forces increase by increasing the edge radius. It is also observed that the cutting forces are higher at
Keywords:
Micro-milling
a rake angle of 0◦ compared with a rake angle of 8◦ . The increase of the cutting forces is mainly associated
Cutting forces with the change of the friction conditions between the tool and workpiece contact. Stability lobes are
Tool wear obtained for different edge radii, rake angles of 0◦ and 8◦ , initial workpiece temperature and different
Chatter measured static run-outs. The predicted stability lobes are compared with the micro-milling force signals
Cutting edge radius transformed into the frequency domain. It is observed that the predicted stability limits result in good
Rake angle correlation with the experimentally obtained chatter free conditions. Also, the stability limits are higher
at smaller edge radii, higher preheating workpiece temperature and positive rake angles.
© 2012 Elsevier B.V. All rights reserved.

1. Introduction cutting forces, effect of the materials grains on the workpiece

Micro-milling is a suitable process for producing complex 3D
geometries for a wide range of materials. Understanding the phys-
ical phenomena affecting the process performance is essential in
order to increase the quality of the micro-milled components.
Research developments in micro-machining have been pre-
viously reviewed. Masuzawa (2000) reviewed a research work
in micro-electro discharge machining, micro-electro chemi-
cal machining, micro-ultrasonic machining, micro-grinding and
mechanical micro-cutting. Later, Liu et al. (2004) have reviewed the
aspects of the mechanics of the micro-cutting operations including
experimental and modelling studies. The reviewed experimen-
tal work includes the size-effect and minimum chip thickness,
elastic-plastic deformation and microstructure effects in micro-
machining. The reviewed modelling studies include molecular
dynamics methods, finite element methods, mechanistic mod-
elling techniques and multiscale modelling. Chae et al. (2006) have
reviewed the efforts in mechanical micro-machining research and
applications, especially the micro-milling operations. They have
focused on aspects including cutting and machine tools, miniature
machine factories, chip formation and minimum chip thickness,
∗ Corresponding author.
E-mail addresses: shukri.afazov@nottingham.ac.uk, shukri.afazov@gmail.com
(S.M. Afazov).
behaviour, tool wear and burrs, testing and modelling, handling
and assembly. They have also discussed the micro-machining from
the macro-machining knowledge in relation to cutting forces, feed
rate estimation, chatter, run-out, sensing methods, process opti-
misation and monitoring. Furthermore, Dornfeld et al. (2006) have
reviewed the following topics related to micro-machining: materi-
als and microstructural effects, machine tools, tooling and sensing,
workpiece and design issues, software and simulation tools, surface
and edge finish.
The aim of this section is to describe the physical phenomena
in micro-milling by considering the above reviews and present the
most recent research developments in the field.
1.1. Wear and edge radius effects
The miniaturisation of components has led to the develop-
ment of new micro-milling cutting tools with small diameters (less
than 30 ␮m) and sharp edges. The most preferable micro-milling
tools for cutting steels or other hard materials are made of tung-
sten carbides. One of the important features in manufacturing the
micro-milling cutters is to decrease the size of the edge radius. The
decrease of the cutting edge radius is limited by the existing tool
manufacturing technologies and the grain size of the corresponding
tool material. Cutting edge radii of 1 ␮m or below are achievable
for carbide materials. For example, Aramcharoen et al. (2008) have
used cutting tools with sharp edges to investigate the size-effect in

0924-0136/$ – see front matter © 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.jmatprotec.2012.12.001
672 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684
micro-milling of H13 hardened steel. It has been explored how the
cutting edge ratio influences on the specific cutting force, surface
finish and burr formation. Coating technologies have been applied
to reduce the wear of the cutting tools. The coatings increase the
cutting edge radius depending on the applied coating thickness.
Aramcharoen et al. (2008) have investigated the wear of different
coatings applied to tungsten carbide tools. The results have shown
that the TiN, TiCN, TiAlN, CrN and CrTiAlN coatings reduce the edge
radius wear as compared to uncoated fine grained carbide end mills.
The tests have also shown that TiN consistently performs best in
micro-milling tool steel based on flank wear, chipping, edge radius
wear, surface finish and burr size. Elkaseer et al. (2010) have exper-
imentally investigated the tool edge wear of three flute fine grained
tungsten carbide tools coated with TiAlN and measured tool edge
radii in the range of 2–5 ␮m. The wear of the tool edge radii has
been investigated at feed rates of 4 and 8 ␮m/tooth, cutting veloc-
ities of 12.5 and 50 m/min and 30 ␮m depth of cut for pearlite and
ferrite materials. Results for increase in the edge radius up to 16 ␮m
have been presented.
The increase of tool edge radius leads to an increase in the
cutting forces. For example, Childs (2010) has carried out finite
element simulations of continuous chip formation where higher
cutting forces have been predicted for larger edge radii at constant
uncut chip thicknesses. Malekian et al. (2009a) have examined the
factors affecting the tool wear in micro-milling using a monitoring
method with various sensors, such as accelerometers, force and
acoustic emission sensors. The signals have been fused through the
neuro-fuzzy method for determining whether the tool is in good
condition or worn. Li and Chou (2010) have investigated the effect
of lubrication in near micro-cutting. They have found that the min-
imum quantity of lubrication reduces the flank wear compared to
dry cutting by about 60%.
1.2. Minimum chip thickness and surface quality
Micro-milling is characterised by a mechanical interaction
between a tool with sharp edges and a workpiece material where
the material removal is achieved mainly with the cutting tool edge.
Depending on the size of the cutting tool edge radius, applied
feed rate and spindle speed, the material can be removed in
the form of chips or just ploughed without forming chips. The
boundary between these two phenomena is known as a mini-
mum chip thickness which depends on the size of the edge radius,
feed rate, workpiece material, cutting velocity and tool-workpiece
interaction. The proportion between the uncut chip thickness
and the tool edge radius known as the cutting edge ratio is in
the range of 0.09–0.4 for different materials, cutting conditions
and tool-workpiece interactions as reviewed by Aramcharoen and
Mativenga (2009). Lai et al. (2008) have studied the micro-milling
by focusing on the micro-cutting edge radius and minimum chip
thickness of copper material using the FEM. Malekian et al. (2012)
have modelled the minimum chip thickness using two approaches
based on the principle of minimum required energy and the infinite
shear strain method. The ploughing phenomenon is characterised
by pushing the material without forming a chip which causes both
plastic deformation and elastic recovery or spring-back effect. The
ploughing phenomenon is undesirable due to the poor resultant
surface finish and burr formation. Therefore, the cutting conditions
need to be adequate for the corresponding edge radius of the cutting
tool to guarantee formation of chips.
Childs et al. (2008) have experimentally studied the minimum
achievable surface roughness with cemented carbide and single
crystal diamond round nosed turning and facing inserts for machin-
ing aluminium and steel. Characteristic variations of the machined
surface profile with feed rate, insert edge sharpness and rough-
ness measurements have been reported. Mian et al. (2009) have
experimentally investigated the effect of the uncut chip thickness,
tool edge radius, and workpiece grain size on the specific cutting
force, burr size, surface finish, and tool wear. It has been concluded
that the ploughing effect significantly increases the specific force
and burr size, and also accelerates tool wear. Ozel et al. (2011) have
investigated the effects of machining parameters on surface rough-
ness, burr formation, and tool wear for uncoated and cBN coated
micro-tools for a Ti6Al4V workpiece.
1.3. Micro-milling cutting forces
The determination of micro-milling cutting forces is associated
with defining the uncut chip thickness as a function of the angle
of rotation and obtaining the relationship between the cutting
forces and uncut chip thickness for the corresponding cutting tool
geometry, cutting velocity and workpiece material. The relation-
ship between cutting forces and uncut chip thicknesses is described
by relevant mathematical formulations. The uncut chip thickness
is associated with the kinematics of the cutting tool. For example,
Kumanchik and Schmitz (2007) have formulated analytic expres-
sion for the uncut chip thickness in milling considering the cycloidal
motion of the teeth, run-out, and uneven teeth spacing. The run-
out plays an important role in micro-milling since the feed rates
are low. For example, assuming that the feed rate is 2 ␮m/tooth and
the total run-out is 3 ␮m, it means that some of the teeth will not
be in contact with the workpiece. The relationship between cutting
forces and uncut chip thickness are determined with experimental,
analytical or numerical approaches.
The experimental methods consist of conducting cutting trials
in orthogonal cutting for different uncut chip thicknesses. Mech-
anistic and analytical approaches have been developed to predict
the cutting forces in orthogonal cutting. Vogler et al. (2003) have
developed a mechanistic model for micro-endmilling that explicitly
accounts for the different phases while machining heterogeneous
material. Kim et al. (2004) have developed a static model of chip
formation in micro-milling processes describing the intermittency
of the chip formation observed at low feed rates. Kang et al.
(2007) have developed an analytical mechanistic model of micro-
endmilling for predicting the cutting forces which considers the
tool-workpiece contact at the flank face. Bissacco et al. (2008) have
developed a theoretical model for cutting force prediction in micro-
milling, taking into account the cutting edge radius size effect, the
run-out and the deviation of the chip flow angle from the inclina-
tion angle. Malekian et al. (2009b) have investigated a mechanistic
modelling of micro-milling forces, with consideration of the effect
of ploughing, elastic recovery, run-out, and dynamics. Afazov et al.
(2010) have predicted the cutting forces in micro-milling of AISI
4340 steel considering the full kinematics of the cutting tool includ-
ing the run-out effect, cutting velocity, tool edge radius, rake angle
and material behaviour at different strain rates and temperatures
using the FEM. Based on this approach, Afazov et al. (2012b) have
predicted and validated the micro-milling cutting forces for AISI
H13 steel considering the material hardness. Jin and Altintas (2011)
have used the slip-line field theory to predict the micro-milling
forces of Brass 260 considering a strain rate dependent flow stress
material model. Also, Jin and Altintas (2012) have used the FEM to
predict the cutting forces for Brass 260.
1.4. Size-effect phenomenon
An important aspect of the micro-milling process is the presence
of size-effect or dependence of strength on the scale of deformation
as observed by a number of researchers. This is mainly due to the
material behaviour at micro-scale as the feed rates in micro-milling
are comparable with the material grain size. Generally, the size-
effect can be described as non-linear increase of the specific cutting
 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684
energy at different micro-machining cutting conditions. Karpat
(2009) has reported four explanations that relate the size-effect to
the material strengthening mechanisms due to (i) the decreasing
number of defects in microstructure, (ii) the increasing strain rate
at the primary shear zone, (iii) the effect of thermal softening and
(iv) the effect of strain gradient plasticity at the deformation zones
at low uncut chip thickness.
Joshi and Melkote (2004) have analytically modelled an ortho-
gonal cutting which incorporates a material constitutive law with
strain gradient dependence of flow stress. The size-effect in the
parallel-sided primary deformation zone has been modelled using
a sharp cutting tool in machining utilising the strain gradient plas-
ticity theory without considering the effect of cutting edge radius.
Liu and Melkote (2006) have examined the material strengthen-
ing effect where the material strength increases nonlinearly as the
uncut chip thickness is reduced to a few microns. They analysed two
material strengthening factors, the contribution of the decrease in
the secondary deformation zone cutting temperature and the strain
gradient strengthening for Aluminium 5083-H116. Later, Liu and
Melkote (2007) have used their developed strain gradient plastic-
ity based FE model of orthogonal micro-cutting for the Aluminium
5083-H116 to examine fundamentally the influence of tool edge
radius on the size-effect. It has been concluded that the tool edge
radius accounts for only part of the size-effect in micro-cutting.
Vollertsen et al. (2009) have presented in their review paper that
size-effects have a strong influence on production processes. They
concluded that the main feature of size-effects in micro-machining
is the flow stress of the material which is influenced by different
types of size-effects and the most important effect in machining
is the increase of the normalised cutting force with decreasing the
uncut chip thickness. Wu and Liu (2010) have proposed a flow stress
model based on the strain gradient plasticity theory for the pro-
cess of micro-cutting of AISI 1045 steel. Afazov et al. (2011) have
considered the size-effect in determining the micro-milling cutting
forces of Ti6Al4V alloy by modelling the material stress flow using
the Johnson Cook (JC) constitutive equation and the strain gradi-
ent plasticity theory. It has been observed that the material model
using the strain gradient plasticity results in better correlation with
the experimentally obtained micro-milling cutting forces for feed
rates less than or equal to 6 ␮m/tooth while the JC material model
predicts more accurately the micro-milling cutting forces for feed
rates of 12 ␮m/tooth.
1.5. Chatter in micro-milling
Chatter is a self-excited vibration between the cutting tool and
the workpiece in micro-milling. It is characterised by poor surface
quality and fast tool wear. Cutting tool damage and reduced mate-
rial removal rate is also observed. Chatter is modelled by solving
the equation of motion in the frequency or time domain where the
cutting forces and modal dynamic parameters at the cutting tool tip
are used. The chatter phenomenon has been extensively researched
in conventional milling in both time and frequency domains.
Rahnama et al. (2009) have extended the work in conventional
chatter to predict the chatter stability lobes in micro-milling. The
process damping parameters have been obtained using the equiv-
alent volume interface between the tool and the workpiece and
incorporated into the model. They have performed experimental
cutting trials to detect the chatter using acoustic emission sen-
sors. Park and Rahnama (2010) have considered the uncertainties
and changes in the dynamics and cutting coefficients in determina-
tion of chatter-free conditions in micro-milling operation through a
robust stability method. Biermann and Baschin (2009) have exper-
imentally obtained the stability lobes at 10 ␮m/tooth feed rate and
spindle speeds in the range of 20,000–35,000 rev/min for different
edge radii. It has been observed that the influence of the cutting
673
edge radius on the process stability is significant. Afazov et al.
(2012a) have developed a new chatter model in the time domain
solution considering the nonlinearities of the micro-milling process
due to velocity dependant, ploughing and shear dominant cutting
forces and the run out effect in micro-milling.
1.6. Dynamics of micro-milling tools
The accurate prediction of the stability limits is greatly affected
by the modal dynamic parameters of the tool-holder-spindle
assembly. The dynamics of the tool-holder-spindle assembly in
conventional milling is mainly determined by hammer testing
with an accelerometer attached to the tool tip. This technique is
not applicable in micro-milling as the accelerometers cannot be
attached at the small edges of the micro-tools. The receptance cou-
pling technique has been mainly used to determine the dynamics
at the tool tip. In this technique, the tool-holder-spindle assembly
is divided into two substructures. The first substructure represents
the lower part of the micro-end-mill and the second substructure
includes the remaining part of the tool and the spindle. The dynam-
ics of the first substructure is obtained using analytical or numerical
approaches. The dynamics of the second substructure is deter-
mined using miniature impact hammer excitation and measuring
the vibrations with accelerometers or laser vibrometers. The fre-
quency response function is then determined after performing the
receptance coupling technique and the modal dynamic parameters
are obtained using fitting techniques. For example, Park et al. (2003)
have enhanced the classical receptance technique by proposing a
method of identifying the tool-holder-spindle assembly dynamics
which include both translational and rotational degrees of freedom.
Filiz and Ozdoganlar (2011) have presented an analytically based
three-dimensional model for micro-endmill dynamics, including
actual cross-section and fluted (pre-twisted) geometry. The three-
dimensional model considers bending and coupled axial/torsional
vibrations.
2. Motivation and objectives
The conducted literature review shows that the physical
phenomena in micro-milling processes have been addressed by a
number of researchers. Further enhancements in modelling and
experimental procedures are required for better understanding all
physical phenomena affecting the process and the quality of the
final micro-milled components. One of the objectives of this paper
is to advance the force model developed by Afazov et al. (2010)
by incorporating the tool wear and the helix angle. Another objec-
tive is to validate the proposed cutting force model and investigate
the effects of the tool wear, rake angle, run-out and workpiece
pre-heating on the cutting forces and process stability.
3. Micro-milling cutting force model
Afazov et al. (2010) have used the following approach to model
the micro-milling cutting forces. First, FE model of orthogonal cut-
ting has been developed to predict the cutting forces. The predicted
cutting forces have been described as a function of the uncut chip
thickness and cutting velocity by mathematical equation. Uncut
chip thickness model considering the full kinematics of the cutting
tool including the run-out effect has been incorporated into the
mathematical cutting force model. Finally, the cutting forces have
been distributed in the x and y direction without taking the effect
of the helix angle into consideration. This has been based on the
assumption that the helix angle does not significantly impact to
the cutting forces at small depths of cut. Using similar approach,
Jin and Altintas (2011, 2012) predicted the cutting forces using
674 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684

slip-line and FE models of orthogonal cutting. They have proposed 3.3. Kinematics of micro-milling tools
a mathematical equation where the predicted cutting forces have
been described as a function of the uncut chip thickness and edge The tool kinematics model presented by Afazov et al. (2010) is
radius. The aim of this section is to show the advancements imple- advanced in this paper by incorporating the helix angle. Fig. 1 shows
mented into the micro-milling forces model developed by Afazov a simplified illustration of milling tool rotating with spindle speed
et al. (2010). (w), moving with feed rate (f) and depth of cut (ap ).
Knowing the time at node A (tA ), the time for all nodes on the
3.1. FE model of orthogonal cutting arc AB can be obtained. This is achieved by sampling the depth of
cut by a number of samples (N). The time for each sampled node
The FE model of orthogonal cutting developed by Afazov et al. (ti ) within the arc AB can be given by:
(2010) for AISI 4340 steel is used in the current research to obtain i(tA − tB )
the cutting forces for different micro-milling conditions includ- ti = tB − (4)
N
ing different cutting velocities, edge radii, rake angles, uncut chip
where tB is the time at node B.
thicknesses and initial workpiece temperatures representing laser
The time tB can be given by:
assisted milling. In addition, a stick–slip friction model with friction
coefficient () of 0.4 and a stick friction model are incorporated into ˛
tB = tA − (5)
the FE model of orthogonal cutting for tool rake angle of 0◦ . In the w
stick–slip friction model, the friction force in the tangential direc- The angle ˛ can be determined with the cosine theorem consid-
tion is defined as min( × Fn , Fs ), where Fn is the normal force and ering the cutting tool radius (R) and the length (H):
Fs is the friction force required to enforce a stick condition. In the  
2R2 − H 2
stick friction model, the friction force in the tangential direction is ˛ = arccos (6)
equal to the friction force required to enforce a stick condition. The 2R2
aim is to predict the cutting forces using the two friction models The length (H) can be obtained as a function of the depth of cut
and analyse which friction model correlates better with the experi- (ap ) and the helix angle (ˇ):
mentally measured cutting forces for a cutting tool with rake angle
of 0◦ . H = ap tan(ˇ) (7)
The time for the previous tooth for each sampled node (ti ) can
3.2. Mathematical cutting force model be given by:
2
In this section, a new mathematical equation is proposed to ti = ti − (8)
wK
describe the cutting forces from orthogonal cutting as a function
of the uncut chip thickness, cutting velocity and edge radius, as where K is the number of flutes.
given by Eq. (1). The uncut chip thickness is obtained from the geometrical rela-
tionships from Fig. 1(b) and given by:
orth
Fc,t = p1 vp2 (1 − ep3 h ) + r p4 (p5 v + p6 )(1 − e(p7 r
p8 +p )h
9 ) (1)  2k

hi = R + L sin wti − + ˛o
where h is the uncut chip thickness, r is the cutting edge radius, K
v is the cutting velocity at the cutting edge and p1 –p9 are force   
constants. Based on the validated model for edge radius of 3.5 ␮m 2k
− R2 − L2 cos2 wti − + ˛o (9)
and rake angle of 8◦ (Afazov et al., 2010), results have been K
generated for the same rake angle, different edge radii and cut-
ting velocities to demonstrate the methodology for obtaining the The length L and angle ˛o can be given by:

constants in Eq. (1). First, the relationship between the FE pre-
L= (xo − xo )2 + (yo − yo )2 (10)
dicted cutting forces and uncut chip thickness for each edge radius y − y  
at constant cutting velocity of 1571 mm/s is given by a two phase o o
˛o = arctan (11)
exponential equation: xo − xo
orth The coordinates of nodes O and O can be given by:
Fc,t = c1 (1 − ec2 h ) + c3 (1 − ec4 h ) (2)
x(O) = fti + Ro sin(wti + o )
After determining the constants (c1 , c2 , c3 and c4 ) from Eq. (2), (12)
it is observed that the constants c3 and c4 are dependent on the y(O) = Ro cos(wti + o )
edge radius. The constants c3 and c4 are then plotted versus the
x(O ) = fti + Ro sin(wti + o )
edge radius (r). It is obtained that the relations between c3 − r and (13)
c4 − r can be described by exponential functions. Eq. (3) shows the y(O ) = Ro cos(wti + o )
relationship between cutting forces, uncut chip thickness and edge
where Ro is the run-out length,  o is the run-out angle, k is the flute
radius.
number.
d6 +d )h
orth
Fc,t = d1 (1 − ed2 h ) + d3 r d4 (1 − e(d5 r 7 ) (3) The time for the previous tooth for each sampled node (ti ) is
obtained by solving Eq. (14) using the Newton–Raphson method.
The cutting velocity is incorporated into Eq. (3) by plotting the  2k
  2(k − 1)
  2k

cutting forces versus the uncut chip thickness at a reference edge R tan wti − cos wti − + Ro tan wti −
radius of 6 ␮m for four cutting velocities and describing the results K K K
with Eq. (3) for each cutting velocity. The constants d1 and d3 are  2k

velocity dependent while the rest of the constants do not change × cos(wti + o ) − Ro tan wti − cos(wti + o ) − fti + fti
K
with the cutting velocity. After plotting, the relationship between  2(k − 1)

d1 − v and d3 − v is described by exponential and linear functions, −R sin wti − − Ro sin(wti + o )
respectively. The full relationship between cutting forces, uncut K
chip thickness, edge radius and cutting velocity is given by Eq. (1). +Ro sin(wti + o ) = 0 (14)
 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684 675

Fig. 1. Kinematics of micro-milling tool considering the run-out and the helix angle: (a) side view; (b) bottom view.

The cutting forces from the orthogonal cutting for each sampled The forces in the x, y and z directions can be obtained by trans-
point are obtained by substituting Eq. (9) into Eq. (1). The micro- forming the cutting forces considering the angle of rotation ().
milling cutting forces are then obtained by summing all sampled ⎡ ⎤
nodes and distributing the cutting forces from the orthogonal cut- Fx ⎡ ⎤ ⎡ Ft ⎤
sin  cos  0
ting into the axial direction. The cutting forces in the axial, cutting ⎢ ⎥ ⎣ ⎢ ⎥
and tangential directions can be given by Eq. (15). ⎣ Fy ⎦ = − cos  sin  0 ⎦ ⎣ Fc ⎦ (16)
N Fz 0 0 1 Fa
F orth
i=1 c,i
Fa = sin(ˇ)
N N 4. Results and discussion
F orth
Fc =
i=1 c,i
cos(ˇ) (15)
N N Figs. 2 and 3 show the fitted and FE predicted cutting forces
F orth
i=1 t,i using the stick–slip friction model with friction coefficient of 0.4
Ft =
N in the cutting and tangential directions, for TiN coated two-flute
676 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684

Fig. 2. FE predicted cutting forces in the cutting direction for rake angle of 8◦ and AISI4340 workpiece material using the stick–slip friction model.

micro-milling cutting tools with diameter of 500 ␮m, rake angle
of 8◦ , edge radii in the range of 1.5–15 ␮m, cutting velocities in the
range of 104.7–4723 mm/s for AISI4340 workpiece material. Eq. (1)
is used to describe the relationship between cutting forces, uncut
chip thickness, edge radius and cutting velocity. The obtained
constants are given in Table 1 after using the fitting methodology
described in Section 3.2. It can be seen that the cutting forces
decrease by increasing the cutting velocity mainly due to increase
of the cutting temperature of the workpiece and the inertia effect.
Also, the cutting forces increase by increasing the edge radius due
to the fact that the contact length increases which creates more
friction. Fig. 3 shows that the cutting forces in the tangential direc-
tion are velocity independent. FE simulations are also performed
for rake angle of 0◦ using the stick–slip and stick friction models

Fig. 3. FE predicted cutting forces in the tangential direction for rake angle of 8◦ and AISI4340 workpiece material using the stick–slip friction model.
 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684 677

25 The cutting forces are measured with a Kistler dynamometer

Tool 1 (w = 40,000 rpm; f = 4 μm/tooth; ap = 70 μm) 9256C2 for each of the measured edge radii for the both cutting
tools and cutting condition. The measured signals are processed
Edge radius, r (μm)

20
Tool 2 (w = 24,000 rpm; f = 8 μm/tooth; ap = 50 μm)
15
10
5 modelled micro-milling forces using the stick–slip and stick fric-
0 seen that the stick friction model correlated better with the experi-
0 100 200 300 400 500
Cutting distance (mm)
Fig. 4. Experimentally measured edge radius due to wear.
described in Section 3.1. The constants for rake angle of 0◦ are
obtained and given in Table 1. The fitted curves are observed to
be in very good correlation with the FE predicted cutting forces,
similar to the results in Figs. 2 and 3. The FE predicted cutting
forces in the tangential direction are also velocity independent for
both stick–slip and stick friction models.
A number of two-flute TiN coated tungsten tools with diameter
of 500 ␮m are initially inspected with a SEM in order to select two
tools with identical edge radii and uniform coating. Edge radii of
1.2 ␮m, rake angles of 0◦ are measured for two tools. The helix
angles are 0◦ at the first 48 ␮m from the cutting tool end and 30◦ for
the rest of the flute. Each tool is attached onto the KERN Evo CNC
milling centre and the static run-out is measured. Spindle speed of
40,000 rpm, feed rate of 320 mm/min (4 ␮m/tooth) and depth of cut
of 70 ␮m are applied for tool 1, while for tool 2, the applied spindle
speed is 24,000 rpm, the feed rate is 384 mm/min (8 ␮m/tooth) and
the depth of cut is 50 ␮m. After 168 mm cutting length on AISI 4340
workpiece material, the cutting tools are removed from the milling
centre and the edge radii are measured for each flute with SEM.
The averaged worn edge radii for up to 672 mm cutting length are
shown in Fig. 4 for both tools. It is observed that the difference
between the measured edge radii for each flute of the tool is in the
range of 0.2–1.5% which is negligible. It can be seen that tool 1 wears
faster for the same cutting length. This is due to the lower feed
rate per tooth where the teeth are in contact with the workpiece
material 2 times more frequently compared to tool 2. Also, the static
run-out is measured after each time the tools are clamped onto
the CNC centre. Run-out lengths (Ro ) are measured in the range
of 0.1–0.5 ␮m for tool 1 and 1–2.1 ␮m for tool 2, respectively, at
a run-out angle ( o ) of 45◦ . It can be seen that the cutting tools
wear slower up to a cutting distance of 320 mm due to the applied
coating while the edge radius increases exponentially when the
contact is between the tungsten carbide tool material and the AISI
4340 workpiece.
and filtered using the DynoWare software. A low-pass filter of 2 kHz
is used where the signal is filtered for frequencies above 2 kHz. The
filtered force signals would decrease the force magnitude at fre-
quencies above 2 kHz. However, the main intention of using this
particular filter is to validate the cutting forces at spindle frequen-
cies lower than 2 kHz. A comparison between the measured and the
tion models for the two-flute TiN coated tungsten carbide tool with
500 ␮m diameter and 0◦ rake angle is shown in Figs. 5–12. It can be
600 700
mental results for the two cutting conditions for all edge radii. This
indicates that the rake angle affects the stick–slip contact between
the tool and the workpiece material. Another observation is that
at large edge radii and small feed rates (see Fig. 8), the stick–slip
and stick models predict relatively close results. This shows that at
large edge radii and small uncut chip thicknesses the stick condition
dominates from the stick–slip friction model which can be associ-
ated with the negative angle caused by the edge radius. Also, the
run-out effect can be seen in Figs. 5–12, particularly in Figs. 9–11.
The variations of the cutting forces in the y direction are caused by
the existence of forced vibrations as described later in the section.
The micro-milling cutting force constants obtained with the stick
friction model are used in this study to predict the process stabil-
ity for cutting tool with rake angle of 0◦ while the cutting force
constants for rake angle of 8◦ using the stick–slip friction model
are used based on the validated results by Afazov et al. (2010).
The measured force signals are used to identify force vibra-
tion for both tools and cutting conditions at different edge radii
and run-out lengths. The measured micro-milling cutting forces
are transformed into the frequency domain using the Fast Fourier
Transformations (FFT). Chatter is identified when the FFT force
magnitude at the tool natural frequency is relatively high. It also
needs to be stated that the low-pass filter of 2 kHz would decrease
the force magnitude in the frequency domain. Fig. 13 shows the
predicted stability lobes and experimental chatter identification.
The stability lobes are predicted by incorporating the cutting force
model presented in this paper into the chatter model developed by
Afazov et al. (2012a). The same modal dynamic parameters in the
x and y directions (natural frequency of 4035 Hz, modal damping
ratio of 0.016 and modal stiffness of 2142 N/mm) are incorporated
in the chatter model. This is made based on the initial assump-
tion that same KERN Evo machining centre and the same overall
micro-milling tool dimensions are used. Fig. 13 shows that the
forced vibrations in the x and y directions for all edge radii occur
at frequency of 3981 Hz which is the natural/chatter frequency
for the tool. There is a difference of 54 Hz between the modelled
(4035 Hz) and the experimentally observed (3981 Hz) tool frequen-
cies. The stability limits are predicted for feed rate of 4 ␮m/tooth,
edge radius of 3.5 ␮m, rake angle of 8◦ and spindle speeds in the

Table 1
Cutting force constants for Eq. (1) at initial workpiece temperature of 25 ◦ C.

Constants Rake angle of 8◦ Rake angle of 0◦ (stick–slip) Rake angle of 0◦ (stick)

Fc Ft Fc Ft Fc Ft

p1 380.8 5000 569 11,000 350.8 85

p2 −0.047 0 −0.079 0 −0.032 0
p3 −0.01 −0.0001 −0.01 −0.0001 −0.015 −0.028
p4 0.78 0.88 0.71 0.84 0.28 0.33
p5 −0.0001 0 −0.00005 0 −0.0006 0
p6 2.32 2.3 2.27 2.4 9.92 7.1
p7 8.82 10 9.63 9.3 14.9 16.1
p8 0.27 0.22 0.2 0.23 0.032 0.036
p9 −20 −20 −20 −20 −20 −20
678 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4
Fx (N)

Fy (N)
2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (º) θ (º)
Fig. 5. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 40,000 rpm, feed rate of 4 ␮m/tooth, edge radius of 1.2 ␮m, rake angle of 0◦ ,
run-out length of 0.5 ␮m and 70 ␮m depth of cut.

6 6
Model (stick friction) Model (stick-slip friction) Model (Stick friction) Model (stick-slip friction)

Experimental Experimental
4 4

Fy (N)
Fx (N)

2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)

Fig. 6. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 40,000 rpm, feed rate of 4 ␮m/tooth, edge radius of 3.3 ␮m, rake angle of 0◦ ,
run-out length of 0.2 ␮m and 70 ␮m depth of cut.

range of 10–100 krpm using the modelled and the experimentally
obtained tool natural frequencies. The results showed that the dif-
ference of 54 Hz results in a very slight shift of the stability lobes
which is negligible. The stability lobes are obtained for tool 1 at
spindle speed of 40,000 rpm, feed rate of 4 ␮m/tooth, different edge
radii due to wear and run-out lengths. It can be seen that the sta-
bility limits depend on the run-out length. The largest depth of
cut at stable cutting is observed at run-out of 1.6 ␮m according to
the model. Four experimental force signals for different edge radii
and run-out lengths of 0.1 ␮m, 0.25 ␮m and 0.5 ␮m indicated that
the micro-milling is conducted with forced vibration as predicted
by the model. The stability limits decrease by increasing the edge
radius due to increase of the cutting forces. Also, the frequency
spectra of the measured forces show that the FFT force magni-
tude of the chatter frequency decreases with increasing the cutting
edge radius. Assuming that the low-pass filter has equally affected
the filtered force signal at the chatter frequency, it can be stated
that the processes damping increases by enlarging the edge radius.
The FFT force magnitude at 40,000 rpm for edge radii of 3.3 ␮m,
5.56 ␮m and 14.5 ␮m is 4.9%, 23.8% and 50.5% lower compared to
edge radius of 1.2 ␮m, respectively. Yusoff et al. (2010) experimen-
tally investigated the effect of process damping at milling using
the wavelength calculated based on the cutting velocity and the
experimentally obtained natural frequency. It has been concluded
that increased cutting edge radius moderately improves process
damping performance.

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4
Fx (N)

Fy (N)

2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)
Fig. 7. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 40,000 rpm, feed rate of 4 ␮m/tooth, edge radius of 5.58 ␮m, rake angle of 0◦ ,
run-out length of 0.25 ␮m and 70 ␮m depth of cut.
 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684 679

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4
Fx (N)

Fy (N)
2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)
Fig. 8. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 40,000 rpm, feed rate of 4 ␮m/tooth, edge radius of 14.5 ␮m, rake angle of 0◦ ,
run-out length of 0.5 ␮m and 70 ␮m depth of cut.

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4
Fx (N)

Fy (N)
2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)
Fig. 9. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 24,000 rpm, feed rate of 8 ␮m/tooth, edge radius of 1.2 ␮m, rake angle of 0◦ ,
run-out length of 2.1 ␮m and 50 ␮m depth of cut.

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4
Fy (N)
Fx (N)

2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)
Fig. 10. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 24,000 rpm, feed rate of 8 ␮m/tooth, edge radius of 3 ␮m, rake angle of 0◦ ,
run-out length of 1.2 ␮m and 50 ␮m depth of cut.

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4
Fy (N)
Fx (N)

2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)
Fig. 11. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 24,000 rpm, feed rate of 8 ␮m/tooth, edge radius of 6.56 ␮m, rake angle of
0◦ , run-out length of 1.8 ␮m and 50 ␮m depth of cut.
680 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684

6 6
Model (stick friction) Model (stick-slip friction) Model (stick friction) Model (stick-slip friction)

Experimental Experimental
4 4

Fy (N)
Fx (N)

2 2

0 0
0 180 360 540 720 900 1080 1260 0 180 360 540 720 900 1080 1260

-2 -2
θ (°) θ (°)
Fig. 12. Experimental and modelled micro-milling forces for AISI 4340 steel at spindle speed of 24,000 rpm, feed rate of 8 ␮m/tooth, edge radius of 12.1 ␮m, rake angle of
0◦ , run-out length of 1.1 ␮m and 50 ␮m depth of cut.

Fig. 13. Experimental and modelled stable micro-milling for spindle speed of 40,000 rpm and feed rate of 4 ␮m/tooth.
 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684
Fig. 14. Experimental and modelled stable micro-milling for spindle speed of 24,000 rpm and feed rate of 8 ␮m/tooth.
Fig. 14 shows the stability limits obtained for tool 2 with spindle
speed of 24,000 rpm, feed rate of 8 ␮m/tooth, different edge radii
and run-out lengths. The measured force signals indicate that for
the edge radii with run-out lengths of 1.8 ␮m and 2.1 ␮m the FFT
force magnitude at 3981 Hz is small. This indicates that the vibra-
tions damp, while at lower run-out lengths the FFT force magnitude
indicates a presence of forced vibrations or chatter. Filiz et al. (2007)
showed that the FFT force magnitudes at the spindle frequency can
indicate the strong effect of the tool run-out. This effect can be also
seen in Fig. 14.
Sensitivity analyses are performed based on the validated cut-
ting force and chatter models. Fig. 15 shows the cutting forces in
the cutting and tangential direction for edge radii of 1.5 and 15 ␮m,
and rake angles of 0◦ and 8◦ at cutting velocity of 1571 mm/s. Based
on the validated results, Eq. (1) with the constants obtained with
the stick–slip friction model for 8◦ rake angle and the stick friction
model for 0◦ rake angle are used to conduct the sensitivity anal-
yses. The results show that the rake angle significantly affects the
cutting forces at small edge radii and high uncut chip thicknesses.
It can be also seen that at edge radius of 15 ␮m and uncut chip
thicknesses smaller than 4 ␮m, the cutting forces at rake angle of
681
0◦ are slightly higher than the forces at rake angle of 8◦ . This indi-
cates that the edge radius acting with negative cutting angle results
in stick dominant friction from the stick–slip friction model. This
observation can also be seen when comparing the modelled and
the experimental cutting forces in Fig. 8.
Fig. 16 shows the stability lobes obtained at feed rate of
4 ␮m/tooth, edge radii of 3.5 ␮m and 15 ␮m, and rake angles of
0◦ and 8◦ . It can be seen that the stability limits are lower for rake
angle of 0◦ due to the higher cutting forces. The same behaviour is
observed for feed rate of 8 ␮m. The stability limits at edge radius of
15 ␮m are slightly affected by the rake angle while the rake angle
affects significantly the stability limits at edge radius of 3.5 ␮m.
This can be explained with the small difference of the cutting forces
at large edge radii and small uncut chip thicknesses for both rake
angles. It can also be seen that the stability limits decrease by
increasing the edge radius.
Results indicate that the cutting conditions must be adequate
for the corresponding stage of wear in order to guarantee stable
cutting. The minimum chip thickness must also be considered in
selection the cutting conditions in other to guarantee the chip for-
mation and avoidance of ploughing. In terms of micro tool designs,
682 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684

r = 3.5 μm r = 15 μm
(a) 100 (b) 100
Fc - rake angle of 0° Ft - rake angle of 0° Fc - rake angle of 0° Ft - rake angle of 0°
90 Fc - rake angle of 8° Ft - rake angle of 8° 90 Fc - rake angle of 8° Ft - rake angle of 8°
80 80
70 70
60 60

Force (N)
Force (N)

50 50
40 40

F
30 30
20 20
10 10
0 0
0 5 10 15 20 0 5 10 15 20
Uncut chip thickness, h (μm) Uncut chip thickness, h (μm)

Fig. 15. Cutting forces predicted with the stick–slip and stick friction models for rake angles of 8◦ and 0◦ , respectively, for: (a) edge radius of 3.5 ␮m; (b) edge radius of 15 ␮m.

f = 4 μm/tooth; r = 3.5 μm f = 4 μm/tooth; r = 15 μm

(a) 150 (b) 150
Rake angle of 8° Rake angle of 8°
Depth of cut, ap (μm)
Depth of cut, ap (μm)

125 Rake angle of 0° 125 Rake angle of 0°

100 100
75 75

50 50

25 25

0 0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Spindle speed, w (rpm) Spindle speed, w (rpm)

(c) f = 8 μm/tooth; r = 3.5 μm (d) 150 f = 8 μm/tooth; r = 15 μm

150
Rake angle of 8° Rake angle of 8°
Depth of cut, ap (μm)

Depth of cut, ap (μm)

125 Rake angle of 0° 125 Rake angle of 0°

100 100
75 75
50 50
25 25
0 0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Spindle speed, w (rpm) Spindle speed, w (rpm)

Fig. 16. Predicted stability lobes at initial workpiece temperature of 25 ◦ C and rake angles of 0◦ and 8◦ : (a) f = 4 ␮m/tooth and r = 3.5 ␮m; (b) f = 4 ␮m/tooth and r = 15 ␮m; (c)
f = 8 ␮m/tooth and r = 3.5 ␮m; (d) f = 8 ␮m/tooth and r = 15 ␮m.

the rake angle must be considered positive in order to avoid the

stick friction condition which leads to increase of the cutting forces
Table 2
and decrease of the stability limits. Cutting force constants for Eq. (1) at 600 ◦ C initial workpiece temperature of AISI
More analyses are performed to investigate the effect of the 4340.
workpiece pre-heating on the process stability. The FE model of
Constants Rake angle of 0◦ (stick)
orthogonal cutting with stick friction model is used to obtain the
cutting forces by applying an initial workpiece temperature of Fc Ft
600 ◦ C for a cutting tool with rake angle of 0◦ . The initial temper- p1 460.26 80
ature represents a workpiece preheating induced by laser assisted p2 −0.058 0
micro-milling as modelled by Ding et al. (2012). The cutting force p3 −0.006 −0.008
p4 0.685 1
constants for Eq. (1) are obtained for the preheated workpiece of
p5 −0.0001 0
600 ◦ C and given in Table 2. Fig. 17 shows the predicted stability p6 1.81 1
limits for workpiece at room and preheated temperature at 600 ◦ C. p7 16.2 11
It can be seen that the stability limits are higher when the work- p8 0.04 0.16
piece is preheated. This is due to the material softening at 600 ◦ C p9 −20 −20
 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684
(a) 300 f = 4 μm/tooth; r = 3.5 μm
Depth of cut, ap (μm)
250
200
150
100
50
0 0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Spindle speed, w (rpm)
f = 8 μm/tooth; r = 3.5 μm
(c) 300
Depth of cut, ap (μm)
250
200
150
100
50
0 0
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Spindle speed, w (rpm)
Fig. 17. Predicted stability lobes at rake angles of 0◦ and initial workpiece temperature of 25 ◦ C and 600 ◦ C: (a) f = 4 ␮m/tooth and r = 3.5 ␮m; (b) f = 4 ␮m/tooth and r = 15 ␮m;
(c) f = 8 ␮m/tooth and r = 3.5 ␮m; (d) f = 8 ␮m/tooth and r = 15 ␮m.
which results in lower cutting forces. It must be also mentioned that
the preheating workpiece temperature increases the wear rate as
reported by Ding et al. (2012).
5. Conclusions
1. An advanced micro-milling cutting force model consider-
ing the run-out, cutting edge radius, cutting velocity, helix
and rake angles, and workpiece preheating is proposed and
validated.
2. Two friction models (stick–slip and stick) are used in the FE
model of orthogonal cutting and investigated by comparison
with experimental micro-milling forces for AISI 4340 work-
piece material. The results showed that the stick friction model
correlates better with the experimentally measured micro-
milling cutting forces for two cutting conditions and different
edge radii measured during wear testing for rake angle of
0◦ .
3. The stability of the process is obtained for a wide range of edge
radii, feed rates and run-out lengths. The results have been com-
pared with experimentally measured force signals transformed
into the frequency domain where good correlation between
modelled and experimental results has been obtained.
4. The rake angle of 0◦ results in higher forces and lower stability
limits compared to rake angle of 8◦ . The increase of the cutting
forces and decrease of the stability limits is more significant for
small edge radii and high uncut chip thicknesses.
5. The modelling results showed that the stability limits increase
for preheated workpiece at 600 ◦ C due to the material softening
and decrease of the cutting forces.
Acknowledgments
The authors wish to acknowledge the Nottingham Innovative
Manufacturing Research Centre (NIMRC) and the Engineering and
Physical Sciences Research Council (EPSRC) for their financial sup-
port of the work.
683
(b) 300 f = 4 μm/tooth; r = 15 μm
600 °C 600 °C
Depth of cut, ap (μm)
25 °C 250 25 °C
200
150
100
50
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Spindle speed, w (rpm)
f = 8 μm/tooth; r = 15 μm
(d) 300
600 °C 600 °C
Depth of cut, ap (μm)
25 °C 250 25 °C
200
150
100
50
10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Spindle speed, w (rpm)
References
Afazov, S.M., Ratchev, S.M., Segal, J., 2010. Modelling and simulation of micro-milling
cutting forces. Journal of Materials Processing Technology 210, 2154–2162.
Afazov, S.M., Ratchev, S.M., Segal, J., 2011. Determination of cutting forces and pro-
cess stability in micro-milling of Ti6Al4V alloy by considering the size-effect
phenomenon. Micro and NanoSystems 3, 199–209.
Afazov, S.M., Ratchev, S.M., Segal, J., Popov, A.A., 2012a. Chatter modelling in micro-
milling by considering process nonlinearities. International Journal of Machine
Tools and Manufacture 56, 28–38.
Afazov, S.M., Ratchev, S.M., Segal, J., 2012b. Prediction and experimental validation
of micro-milling cutting forces of AISI H13 steel at harness between 35 and 60
HRC. International Journal of Advanced Manufacturing Technology 62, 887–899.
Aramcharoen, A., Mativenga, P.T., 2009. Size effect and tool geometry in micromilling
of tool steel. Precision Engineering 33, 402–407.
Aramcharoen, A., Mativenga, P.T., Yang, S., Cooke, K.E., Teer, D.G., 2008. Evalua-
tion and selection of hard coatings for micro milling of hardened tool steel.
International Journal of Machine Tools and Manufacture 48, 1578–1584.
Biermann, D., Baschin, A., 2009. Influence of cutting edge geometry and cutting
edge radius on the stability of micromilling processes. Production Engineering
3, 375–380.
Bissacco, G., Hansen, H.N., Slunsky, J., 2008. Modelling the cutting edge radius size
effect for force prediction in micro milling. CIRP Annals – Manufacturing Tech-
nology 57, 113–116.
Chae, J., Park, S.S., Freiheit, T., 2006. Investigation of micro-cutting operations. Inter-
national Journal of Machine Tools and Manufacture 46, 313–332.
Childs, T.H.C., 2010. Surface energy, cutting edge radius and material flow stress size
effects in continuous chip formation of metals. CIRP Journal of Manufacturing
Science and Technology 3, 27–39.
Childs, T.H.C., Dornfeld, D., Lee, D.E., Min, S., Sekiya, K., Tezuka, R., Yamane, Y., 2008.
The influence of cutting edge sharpness on surface finish in facing with round
nosed cutting tools. CIRP Journal of Manufacturing Science and Technology 1,
70–75.
Ding, H., Shen, N., Shin, Y., 2012. Thermal and mechanical modeling analysis of
laser-assisted micro-milling of difficult-to-machine alloys. Journal of Materials
Processing Technology 212, 601–613.
Dornfeld, D., Min, S., Takeuchi, Y., 2006. Recent advances in mechanical micromach-
ining. CIRP Annals – Manufacturing Technology 55, 745–768.
Elkaseer, A.M., Popov, K.B., Dimov, S.S., Minev, R., 2010. Material microstruc-
ture effect-based investigation of tool wear in micro-endmilling of
multi-phase materials. In: Seventh International Conference on Multi-
Material Micro Manufacturing, Bourg en Bresse and Oyonnax, France,
pp. 188–191.
Filiz, S., Ozdoganlar, B., 2011. A three-dimensional model for the dynamics of micro-
endmills including bending, torsional and axial vibrations. Precision Engineering
35, 24–37.
Filiz, S., Conley, C., Wasserman, M., Ozdoganlar, B., 2007. An experimental
investigation of micro-machinability of copper 101 using tungsten carbide
micro-endmills. International Journal of Machine Tools and Manufacture 47,
1088–1100.
684 S.M. Afazov et al. / Journal of Materials Processing Technology 213 (2013) 671–684
Jin, X., Altintas, Y., 2011. Slip-line field model of micro-cutting process with round
tool edge effect. Journal of Materials Processing Technology 211, 339–355.
Jin, X., Altintas, Y., 2012. Prediction of micro-milling forces with finite element
method. Journal of Materials Processing Technology 212, 542–552.
Joshi, S., Melkote, S., 2004. An explanation for the size-effect in machining using
strain gradient plasticity. Journal of Manufacturing Science and Engineering 126,
679–684.
Kang, I., Kim, J.S., Kim, J.H., Kang, M., Seo, Y., 2007. A mechanistic model of cut-
ting force in the micro end milling process. Journal of Materials Processing
Technology 187–188, 250–255.
Karpat, Y., 2009. Investigation of the effect of cutting tool edge radius on mate-
rial separation due to ductile fracture in machining. International Journal of
Mechanical Sciences 51, 541–546.
Kim, C., Mayor, J., Ni, J., 2004. A static model of chip formation in microscale milling.
Journal of Manufacturing Science and Engineering 126, 710–719.
Kumanchik, L.M., Schmitz, T.L., 2007. Improved analytical chip thickness model for
milling. Precision Engineering 31, 317–324.
Lai, X., Li, H., Li, C., Lin, Z., Ni, J., 2008. Modelling and analysis of micro scale milling
considering size effect, micro cutter edge radius and minimum chip thickness.
International Journal of Machine Tools and Manufacture 48, 1–14.
Li, K.-M., Chou, S.-Y., 2010. Experimental evaluation of minimum quantity lubri-
cation in near micro-milling. Journal of Materials Processing Technology 210,
2163–2170.
Liu, K., Melkote, S., 2006. Material strengthening mechanisms and their contribution
to size effect in micro-cutting. Journal of Manufacturing Science and Engineering
128, 730–738.
Liu, K., Melkote, S., 2007. Finite element analysis of the influence of tool edge
radius on size effect in orthogonal micro-cutting process. International Journal
of Mechanical Sciences 49, 650–660.
Liu, X., DeVor, R.E., Kapoor, S.G., Ehman, K.F., 2004. The mechanics of machining
at the micro scale: assessment of the current state of the science. Journal of
Manufacturing Science and Engineering 126, 666–678.
Malekian, M., Mostofa, M.G., Park, S.S., Jun, M.B.G., 2012. Modeling of minimum
uncut chip thickness in micro machining of aluminum. Journal of Materials
Processing Technology 212, 553–559.
Malekian, M., Park, S.S., Jun, M., 2009a. Tool wear monitoring of micro-milling oper-
ations. Journal of Materials Processing Technology 209, 4903–4914.
Malekian, M., Park, S., Jun, M., 2009b. Modelling of dynamic micro-milling cut-
ting forces. International Journal of Machine Tools and Manufacture 49,
586–598.
Masuzawa, T., 2000. State of the art of micromachining. CIRP Annals – Manufacturing
Technology 49, 473–488.
Mian, A.J., Driver, N., Mativenga, P.T., 2009. Micromachining of coarse-
grained multi-phase material. Proceedings of the Institution of
Mechanical Engineers. Part B: Journal of Engineering Manufacture 223,
337–385.
Ozel, T., Thepsonthi, T., Ulutan, D., Kaftanoglu, B., 2011. Experiments and finite
element simulations on micro-milling of Ti–6Al–4V alloy with uncoated
and cBN coated micro-tools. CIRP Annals – Manufacturing Technology 60,
85–88.
Park, S.S., Altintas, Y., Movahhedy, M., 2003. Receptance coupling for end mills.
Journal of Machine Tools and Manufacture 43, 889–896.
Park, S.S., Rahnama, R., 2010. Robust chatter stability in micro-milling operations.
CIRP Annals – Manufacturing Technology 59, 391–394.
Rahnama, R., Sajjadi, M., Park, S.S., 2009. Chatter suppression in micro end
milling with process damping. Journal of Materials Processing Technology 209,
5766–5776.
Vogler, M., DeVor, R., Kapoor, S., 2003. Microstructure-level force prediction model
for micro-milling of multi-phase materials. Journal of Manufacturing Science
and Engineering 125, 202–221.
Vollertsen, F., Biermann, D., Hansen, H.N., Jawahir, I.S., Kuzman, K., 2009. Size effects
in manufacturing of metallic components. CIRP Annals – Manufacturing Tech-
nology 58, 566–587.
Wu, J., Liu, Z., 2010. Modeling of flow stress in orthogonal micro-cutting process
based on strain gradient plasticity theory. International Journal of Advanced
Manufacturing Technology 46, 143–149.
Yusoff, A.R., Tuner, S., Taylor, C.M., Sims, N.D., 2010. The role of tool geometry
in process damped milling. International Journal of Advanced Manufacturing
Technology 50, 883–895.