Finite element simulation of high speed micro milling in the presence of tool run-out with experimental validations

Aldo Attanasio, Andrea Abeni, Tuğrul Özel, Elisabetta Ceretti

Research output: Contribution to journalArticlepeer-review

20 Scopus citations


Micro milling process of CuZn37 brass is considered important due to applications in tool production for micro moulding and micro replication technology. The variations in material properties, work material adhesion to tool surfaces, burr formation, and tool wear result in loss of productivity. The deformed chip shapes together with localized temperature, plastic strain, and cutting forces during micro milling process can be predicted using finite element (FE) modeling and simulation. However, tool-workpiece engagement suffers from tool run-out affecting process performance in surface generation. This work provides experimental investigations on effects of tool run-out as well as process insight obtained from simulation of chip flow, with and without considering tool run-out. Scanning electron microscope (SEM) observation of the 3D chip shapes demonstrates ductile deformed surfaces together with localized serration behavior. FE simulations are utilized to investigate the effects of micro milling operation, cutting speed, and feed rate on forces, chip flow, and shapes. Predicted cutting forces and chip flow results from simulations are compared with force measurements, tool run-out, and chip morphology revealing reasonable agreements.

Original languageEnglish (US)
Pages (from-to)25-35
Number of pages11
JournalInternational Journal of Advanced Manufacturing Technology
Issue number1-4
StatePublished - Jan 16 2019

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering


  • Finite element method (FEM)
  • Force
  • Micro machining


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