FEM simulation of micromilling of CuZn37 brass considering tool run-out

Micro-milling process of CuZn37 brass is considered important due to applications in tool production for micro replication technology. Variation in material properties, work material adhesion to tool surfaces, burr formation, and tool wear result in loss of productivity. Chip shapes together with localized temperature, plastic strain, and cutting forces during micro milling process can be predicted using Finite Element (FE) modelling 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 3D FE simulations 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 cutting speed on cutting forces. Cutting force and chip morphology results from simulations are compared with force measurements, and actual chip morphology acquired by SEM revealing reasonable agreements.