Modeling of cutting force in micro-milling considering asymmetric tool wear

The asymmetric tool wear caused by the tool runout significantly affects the cutting force in micro-milling. In this study, an improved cutting force model considering asymmetric tool wear is constructed for predicting the micro-milling force. Firstly, by analyzing the effect of asymmetric tool wear on uncut chip thickness (UCT), shear/ploughing force, and friction force in the flank wear region, the analytical micro-milling force model considering asymmetric tool wear is derived. Secondly, the multiple parameters in the model are determined by the proposed laser measurement, wear image detection, and mechanical parameter identification methods. Finally, the cutting force and tool wear experiments are designed to validate the proposed model. Experimental results show that the established cutting force model improves the accuracy of cutting force prediction by 6.36% compared with the conventional cutting force model without considering the asymmetric wear.