Analysis and simulation of size effects in micromilling

In this paper the influence of a downscaling of the tool diameter and of the machining parameters on the milling process is analyzed. Starting with an analysis of the cutting edge radius of the tools, the influence of the downscaling on the process is determined by analyzing the surface quality and the cutting forces. The simulation system NCChip, which has been developed at the ISF, is used to simulate the cutting forces when using small tool diameters. This simulation is also used to predict the cutting forces for more complex engagement conditions, like increasing radial immersion or milling of a slot pocket. Additionally, the effects of a downscaling on the tool deflection are analyzed, and strategies to reduce these effects are investigated.