Modelling of micro-milling by considering tool run-out and ploughing regime

The accuracy in micro-milling is strongly affected by the phenomena of tool run-out. The discordance between the tool edge effective and theoretical trajectories increases the tool wear and it negatively affects the quality of the machined surface. The tool run-out should be considered in machining modelling in order to accurately predict how the cutting force changes as the process parameters change. This paper describes the structure of an analytical model which computes the cutting force by considering the tool run-out and the concurrent presence of ploughing- and shearing- dominated cutting regimes. The model was finally calibrated by considering micro-machining on difficult-to-cut material.