Surface Prediction Model of Micro-Endmilling Based on the Geometries and Tool Runout

In this study, a surface prediction model for micro-endmilling including the geometry and manufacture error of micro flat endmill and tool runoutis proposed. In micro-endmilling, runout and the geometry and manufacture error inherent to micro toolsseriously impact the quality of the micro-cutting process in comparison to macroendmilling. This is because the specific cutting energy and feed per tooth to tool radius are very large and thus, the above-mentioned errors work in combination. Therefore, in the proposed numerical model for predicting the micro-endmilling surface, error variables such as tool dish, tool eccentricity, tilted edge parts and runout were applied. Finally, the results generated by the proposed numerical model were analyzed according to feedrate and tool rotational velocity and the results of micro-endmilling experiments. In results of experiment, the predicted surface roughness was different from the real surface roughness, but the variation of predicted surface roughness and surface profiles was very similar to the real surface roughness.