Influence of the worn tool affected by built-up edge (BUE) on micro end-milling process performance: A 3D finite element modeling investigation

Micro milling process has been utilized for several decades due to the flexibility of the process in producing complex components. The small size of the process makes the comprehension of cutting phenomenon details more difficult. This study presents a 3D finite element modeling (3D FEM) approach for the micro end-milling process of Aluminum material (Al6082-T6). 3D FEM simulations are carried out in full slot micro end-milling and contour up milling. The model first implements the actual tool geometry and then the effect of typical built-up edge (BUE) on the milling tool. The influence of BUE on the process performance is investigated by comparing the predicted 3d chip flow shape, burr formation and cutting forces with experiments conducted on an ultra-high precision micro milling center. Simulations indicate that BUE has significant impact on the chip shape and chip load for different teeth engagements. Results prove that also burr height is negatively affected by the presence of BUE. The predicted micro milling cutting forces resulted affected by BUE with different teeth engagements. Analysis of experimental measured forces indicates comparable results in respect to simulated profiles confirming the usefulness of the develop 3D FE modelling approach.