An improved cutting force model in micro-milling considering the comprehensive effect of tool runout, size effect, and tool wear

Tool runout, cutting edge radius-size effect, and tool wear have significant impacts on the cutting force of micro-milling. In order to predict the micro-milling force and the related cutting performance, it is necessary to establish a cutting force model including tool runout, cutting edge radius, and tool wear. In this study, an instantaneous uncut chip thickness (IUCT) model considering tool runout, a nonlinear shear/ploughing coefficient model including cutting-edge radius, and a friction force coefficient model embedded with flank wear width are respectively constructed. By integrating the IUCT, the nonlinear shear/ploughing coefficient and the friction force coefficient, a comprehensive micro-milling force model including tool runout, cutting edge radius, and tool wear is derived. Experiment results show that the proposed comprehensive model is efficient to predict the nonlinear cutting force of micro-milling with variable tool runout, cutting edge radius, and tool wear.