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Procedia CIRP 00 (2017)

Procedia 000–000
CIRP 87 (2020) 95–100
www.elsevier.com/locate/procedia
5th CIRP CSI 2020
5th CIRP CSI 2020
Milling parameter and tool wear dependent surface quality in micro-milling
Milling parameter28th and CIRP tool wear
Design dependent
of brass
Conference, surface
May 2018, Nantes, quality
France in micro-milling
of brass
AStephan
new methodologya,* to analyzea
Dehen , Eric Segebade , Michael Gerstenmeyer the functionala,and physical
Frederik Zangeraarchitecture
, Volker Schulzeof
a

existing products
Stephan Dehen a,*
, Ericfor an assembly
Segebade a oriented product
, Michael Gerstenmeyer a
, Frederik family
Zangeraidentification
, Volker Schulzea
wbk Institute of Production Science, Karlsruhe Institute of Technology (KIT), Kaiserstr. 12, 76131 Karlsruhe, Germany
a

* Corresponding author.
a
wbkTel.:
Institute Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
+49-721-608-42455; fax: +49-721-608-45004;
of Production Science, Karlsruhe Institute E-mail address:(KIT),
of Technology stephan.dehen@kit.edu
Kaiserstr. 12, 76131 Karlsruhe, Germany
* Corresponding author. Tel.: +49-721-608-42455; fax: +49-721-608-45004; E-mail address: stephan.dehen@kit.edu
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
*Abstract
Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
Short life-time and high tool costs still remain major constraints for the micro-milling process. Understanding the wear mechanisms and their
effects on the workpiece quality is essential for efficient tool usage. Usually, wear increases the cutting forces and reduces the emerging surface
Short life-time and high tool costs still remain major constraints for the micro-milling process. Understanding the wear mechanisms and their
quality during the micro-milling process. Due to high tool costs, cutting parameters are usually chosen for optimal tool lifetime and/or process
effects on the workpiece quality is essential for efficient tool usage. Usually, wear increases the cutting forces and reduces the emerging surface
time rather than optimal surface quality.
Abstract
quality during the micro-milling process. Due to high tool costs, cutting parameters are usually chosen for optimal tool lifetime and/or process
The scope of this paper is to investigate the correlation of the process parameters, strategy and wear status of the tool on the resulting surface
time rather than optimal surface quality.
topography.
InThe
today’s To reach this goal, micro-milling experiments were conducted, andincustomization
which severalisgrooves were milled using two end milling tools,
scopebusiness environment,
of this paper the trendthe
is to investigate towards more of
correlation product varietyparameters,
the process strategy andunbroken.
wear statusDue oftothe
this development,
tool the need
on the resulting of
surface
new and
agile and reconfigurable
worn, with a diameter
productionof 1.5 mm and
systems four cutting
emerged to edges.
cope with The cutting
various speed and
products and feed werefamilies.
product varied, asTowell as the
design andcutting direction.
optimize Brass
production
topography. To reach this goal, micro-milling experiments were conducted, in which several grooves were milled using two end milling tools,
was chosenwell
systems as workpiece material to ensure a constant wear state of the tools duringaretheneeded.
experiments. During the cutting process the process
new andasworn, as toachoose
with diameter theofoptimal
1.5 mmproduct
and fourmatches, product
cutting edges. Theanalysis
cuttingmethods
speed and feed were Indeed, most
varied, as wellofasthe
theknown
cuttingmethods
direction.aim to
Brass
forces
analyze were recorded
a product and examined
or one product family for their magnitude
on the aphysical and frequency response. Furthermore, the grooves were analyzed optically for their
was chosen as workpiece material to ensure constantlevel.
wearDifferent product
state of the toolsfamilies,
during thehowever, may differ
experiments. largely
During in termsprocess
the cutting of the number and
the process
surface roughness.
nature
forcesofwere
components.
recorded and Thisexamined
fact impedes an efficient
for their comparison
magnitude and choice
and frequency of appropriate
response. Furthermore,product family combinations
the grooves were analyzedfor the production
optically for their
The roughness
system. shows in most cases slightly higherexisting
values for the specimen
in view manufactured with and
the worn toolarchitecture.
than the ones done
aimwith
is tothe new
surfaceAroughness.
new methodology is proposed to analyze products of their functional physical The cluster
tool.products
these The biggestin influence
new on the
assembly surface
oriented roughness
product results
families for from
the the feed rate,ofwhile
optimization cutting
existing speedlines
assembly and milling
and the strategy
creation have
of a smaller
future influence.
reconfigurable
The roughness shows in most cases slightly higher values for the specimen manufactured with the worn tool than the ones done with the new
The measured cutting
assembly forces show similar tendencies, than the resultingofsurface roughness. The results show also a significant influence of and
tool
tool. Thesystems. Based
biggest influence ononDatum Flow Chain,
the surface the physical
roughness results from structure
the feed the
rate,products is analyzed.
while cutting Functional
speed and milling subassemblies
strategy have aare identified,
smaller influence.
wear
aThe on
functionalthe vibration
analysis behavior during the process, while the influence of feed rate is mostly negligible. This results partly from the greater tool
measured cuttingisforces
performed. Moreover,
show similar a hybridthan
tendencies, functional and physical
the resulting architectureThe
surface roughness. graph (HyFPAG)
results show also is the output which
a significant depicts
influence the
of tool
runout and
similarity bigger deviation
between product of the cutting
families bythe edges. design support to both, production system planners and product designers. An illustrative
providing
wear on the vibration behavior during process, while the influence of feed rate is mostly negligible. This results partly from the greater tool
example
runout andof abigger
nail-clipper is used
deviation of theto cutting
explainedges.
the proposed methodology. An industrial case study on two product families of steering columns of
© 2020 The Authors.
thyssenkrupp Published
Presta France is thenbycarried
Elsevier outB.V.
to give a first industrial evaluation of the proposed approach.
© 2020
This The
is The
an Authors.
open access Published
article underby Elsevier
the CC B.V.B.V.
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
©© 2017
2020 The Authors.
Authors. Published
Published byby Elsevier
Elsevier B.V.
This is an open
Peer-review access
under article under
responsibility of the
the CC BY-NC-ND
scientific license
committee (http://creativecommons.org/licenses/by-nc-nd/4.0/)
of the 5th CIRP CSI 2020
Peer-review under
This is an open
Peer-review responsibility
access
under article under
responsibility ofofthe
thescientific
CC BY-NC-ND
scientific committee
committee of
ofthe
license 28th CIRPCSI Design
2020Conference 2018.
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
the 5th CIRP
Peer-review under responsibility of the scientific committee of the 5th CIRP CSI 2020
Keywords:Assembly;
Keywords: micro milling;
Designroughness;
method; wear
Family identification
Keywords: micro milling; roughness; wear

1.1.Introduction
Introduction of the
of copper and zinc
product rangethat andhas higher strength
characteristics and hardness
manufactured than
and/or
1. Introduction pure copper.
assembled
of copper in andthis
zincsystem.
that hasIn this
highercontext,
strength the and
mainhardness
challenge in
than
For over
Due to more
the than fast 5’000 years, copper
development in andtheits alloys
domain played
of The micro-milling
modelling
pure copper.and analysis process is defined
is now as a to
not only cutting
copeprocess with
with single
an For
important
communication
over more roleandin the
than an economic
ongoing
5’000 and social
trend
years, copper of development
anddigitization
its alloys playedandof products,
geometrical
The definedproduct
a limited
micro-milling cuttingis
process edges
range orand
defined astool
existing diameters
product
a cutting ranging
families,
process with
mankind
digitalization,[1]
an important role and by
manufacturing2014 had
in the economic reached
enterprises a historic
are facing
and social maximum
important
development of from
but around (1-999
also to bedefined
geometrical µm)
able to analyze [2].
cutting and It
edges has
to and established
compare itself in the
products toranging
tool diameters define
consumption
challenges
mankind in of
[1] and 27by
today’smillion
2014 tonnes
market worldwide.
had environments:
reached Copper,
a historic which is new
a continuing
maximum micro
from machining
product
around families.
(1-999scene It due
µm) to
beits
can[2]. It superior
observed removal
that
has established rate,existing
classical
itself higher
in the
mainly
tendency
consumption used
towards because
of 27reduction of its high
of product
million tonnes electrical
development
worldwide. and
Copper, thermal
times
which precision
andis product and flexibility
families are
micro machining regrouped
scene compared
due to in to
itsfunction other
superiorof micro production
clients rate,
removal or features.
higher
conductivity,
shortened
mainly product
used shows
because further
lifecycles. Inpositive
of its high aspects
addition, there isinan
electrical combination
and increasing
thermal processesassembly
However,
precision [3].flexibility
and Micro-milling
oriented also to
product
compared hasother
familiessomearedisadvantages.
hardly
micro to find.
production
with alloying elements (e.g. Zn, Sn or Pb) such as good While the cutting depth a p in normal cutting processes is
demand of customization,
conductivity, shows further being at theaspects
positive same time in a global
in combination On the product
processes family level,also
[3]. Micro-milling products differ disadvantages.
has some mainly in two
machinability,
competition with bactericidal
competitors effect
all and
over high
or corrosion
the world. resistance.
This as trend, usually
main greater thandepth
characteristics: thethe
(i) cutting
anumber radius and the processes
rβ cutting
of components material
and (ii) can
the
with alloying elements (e.g. Zn, Sn Pb) such good While the cutting p in normal is
One
which of the most
is inducing
machinability, important copper
the development
bactericidal alloys
effect and high is
from brass, a combination
macro resistance.
corrosion to micro be
type assumed to
of components
usually be
greater than(e.g. homogeneous,
mechanical,
the cutting these cutting
radiuselectrical,
rβ and the mechanisms
electronical).
material can
markets,
One of the results in diminished
most important copperlot sizesis brass,
alloys due toa combination
augmenting change
be in micro-milling.
Classical
assumed methodologies
to be homogeneous, Due to anthese
considering extremely
mainly small
single
cutting ratio of
products
mechanisms
product varieties (high-volume to low-volume production) [1]. or solitary,
change already existing
in micro-milling. Due product families small
to an extremely analyzeratiothe
of
2212-8271 © 2020 The Authors. Published by Elsevier B.V.
To cope with this augmenting variety as well as to be able to product structure
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
on a physical level (components level) which
identify
2212-8271
Peer-review possible
©under The optimization
2020 responsibility
Authors. of
Published potentials
by Elsevier
the scientific in ofthe
B.V.
committee existing
the 5th causes difficulties regarding an efficient definition and
CIRP CSI 2020
This is an open
production access article
system, under the CCtoBY-NC-ND
it is important license knowledge
have a precise (http://creativecommons.org/licenses/by-nc-nd/4.0/)
comparison of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the 5th CIRP CSI 2020
2212-8271 © 2020 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th 5th CIRP
DesignCSI 2020 2018.
Conference
10.1016/j.procir.2020.02.024
96 Stephan Dehen et al. / Procedia CIRP 87 (2020) 95–100
2 Author name / Procedia CIRP 00 (2019) 000–000

cutting radius to chip thickness, various effects such as chip Nomenclature

thickness effect [4], ploughing [5] and other size effects [6]
gain in importance, leading to increased tool wear and D tool diameter
shortened tool life. z number of cutting edges
The most common types of wear in micro-milling are of
abrasive or adhesive nature. Often, material adhesion on the vc cutting speed
cutting edge leads to increased cutting forces and thus to higher ae radial overlap
wear. This can occur on the flanks, surfaces or outer edges of ap cutting depth
the tool [7]. In addition, it is not easy to track tool behavior to fz feed per tooth
a critical state of wear, as micro milling tools often break
prematurely due to their fragile structure [8]. Fc cutting force
Since the workpiece-tool interaction in micro-milling is a Fp passive force
rather complex mixture of cutting, rubbing and burnishing
depending on the current geometry of the tool and is subject to
abrupt changes due to wear, it is almost impossible to predict Experimental setup
the resulting surface roughness [7]. According to Oliaei and
Karpat [9] the resulting surface roughness Ra and Rz correlates The experiments were carried out with a five-axis high-
with the wear volume of the tool during micro-milling of precision micro-milling machine tool KERN Pyramid Nano
AISI 420. from KERN Microtechnik GmbH. It has hydrostatic axes with
So far, many studies have been carried out to investigate the a position accuracy of 1 µm, a maximum acceleration above
influence of different process parameters and tool geometries 1 g and a maximum spindle speed of 50'000 min-1. The tools
on the wear behavior of the tool. It has been shown that tool were clamped with the Tribos clamping system of Schunk
wear in micro-milling behaves similarly to macro-milling when GmbH & Co. KG, with a dynamic rotational accuracy below
the cutting speed vc is increased [8]. The feed fz also has a large 3 µm. For the tests, two end mills with four cutting edges and
influence on the process result. If the correct choice is made, a a diameter of D = 1.5 mm were used. The tools were made of
constant chip behavior is triggered, which leads to lower cemented carbide without coating. One tool was new, while the
cutting force fluctuations and thus to a more uniform surface other was already in a worn condition (see section 2.1). Both
quality [10]. If the feed per tooth fz is too small, it may happen tools were analyzed with the confocal light microscope Infinite
that not every tooth produces a chip, but only rubs against the Focus from Alicona Imaging GmbH.
surface [11]. Aurich et al.[12] investigated the influence of the A series of face milling experiments in the copper alloy
spindle tilt angle on the resulting surface and chip formation. CuZn39Pb3 with the new and worn tool was performed. The
He showed that a small tilt angle leads to a surface with low correspondent setup is illustrated in Fig. 1.
roughness and smaller shape deviations. The influence of
cutting parameters on the micro-milling of CuZn39Pb was
analyzed by Tamborlin et al. [13]. They showed that the main
influence on the resulting surface roughness is caused by the
feed per tooth, while the cutting depth and overlap only have a
small affect. They did not detect the occurrence of ploughing
effects, since their minimal feed was above the radius of the
peripheral cutting edge. An investigation of cutting parameters
on wear and cutting forces during the micro-milling of pure Fig. 1. Setup of the conducted experiments
copper was performed by Rahman et al. [14] in 2001. They
discovered, that wear behavior was mostly of abrasive nature The material was chosen, due to its good machinability,
on the tool corner radii. The wear was non-uniform, therefore which ensures a constant state of tool wear during the
leading to great unbalance and premature tool breakage. experiments. Cutting speed, feed per tooth and the rotation
However, nearly no investigations were carried out on the direction were varied full factorial, while the cutting depth and
influence of different cutting parameters and wear conditions the overlap remained constant. The selected parameters are
on the resulting surface quality. Especially with very ductile shown in Table 1. All experiments were performed three times.
materials, such as copper and its alloys, the choice of ideal
cutting parameters can lead to an optimized cutting behavior by Table 1. Cutting parameters for the experiments.
reducing the material adhesion on the cutting edges, reducing Cutting parameters Value
the unbalance of the tool and increasing the surface quality. Cutting speed vc 25, 50, 75, 100 m/min
This paper analyses the influence of cutting parameters, Feed per tooth fz 5, 10, 15 µm
milling strategy and tool wear on the resulting surface
Rotation direction Up-/down-milling
roughness.
Cutting depth ap 50 µm
Overlap ae 375 µm
 Stephan Dehen et al. / Procedia CIRP 87 (2020) 95–100 97
Author name / Procedia CIRP 00 (2019) 000–000 3

During milling, the passive and active forces were measured new tool. In both cases the standard deviation is larger for the
with a three-axis dynamometer from Kistler Instrumente AG. It worn tool. This indicates non-uniform abrasive face and outer
has a maximum measuring range of ± 250 N, a threshold edge wear too.
value of 0.002 N and a natural frequency of 5.5 kHz. Due to the The tool runout, shown in Fig. 3, shows a larger value and
high measuring rate of 3333 Hz, it is possible to perform a deviation for the worn tool, than for the new tool, which could
Short-Time-Fourier transform to analyze the cutting force for introduce a larger unbalance and therefore a worse vibration
its frequency composition. This enables the measuring of behaviour.
cutting edges in contact per revolution. Due to the limited
measuring rate, however, only the measurements for a cutting
speed of vc = 50 m/min could be analyzed.
The resulting surfaces and their roughness were scanned
with a confocal light microscope µSurf from NanoFocus AG
with a magnification of up to 100x, a lateral resolution of
0.2 µm and a vertical resolution of 1 nm.

2. Results and Discussion

Fig. 3. Measured tool runout for the new (a) and worn (b) tool.
2.1. Tool measurements

The 3D confocal light microscopic measurements of the end
mills are displayed in Fig. 2 and Table 2.
2.2. Cutting forces
The measured cutting forces of the experiments are shown
in Fig. 4. As can be seen, the cutting forces of the worn tool (b)
during the down-milling process are higher than those of the
new tool (a). This could be explained by the locally larger
cutting edge due to wear, which leads to a local negative rake
angle and thus to ploughing effects and higher cutting forces.
For both tools, the average cutting forces increase with the
feed per tooth, while for the new tool the cutting speed has
almost no effect and a low reduction effect for the worn tool. A
higher feed per tooth leads to a greater chip cross section and
thus to higher cutting forces. When milling upwards, the
cutting forces of the worn tool (d) are also higher than for the
new tool (c). In addition, the cutting forces increase with rising
feed rate during up-milling. They also grow with the cutting
speed for the new tool, while remaining constant for the worn
tool. The standard deviations of the cutting force for both

Fig. 2. Display of measured micro-milling new (a-b) and worn (c-d) micro-
milling tool.

Table 2. Measured dimensions of the micro-milling tools

Dimension New tool Worn tool
Tool diameter D / µm 1482.7 1475.1
Radius of peripheral cutting edge / µm 13.88 ± 1.01 15.12 ± 2.10
Radius of end cutting edge / µm 12.56 ± 0.48 16.90 ± 2.41
The new tool (a-b) shows a clear rake face and intact cutting
edge, while the worn tool (c-d) exhibits combined face and
outside edge wear (marked red), as well as material adhesion
on the the rake face. According to the measured data, the tool
diameter of the worn tool is 7.6 µm smaller than from the new Fig. 4. Display of the cutting forces, measured during the experiments.
First row: down-milling with the new (a) and worn (b) tool. Second row:
tool. The average radius of the peripheral cutting edge, as well up-milling with the new (c) and worn (d) tool.
as of the end cutting edge is large for the worn tool, as for the
98 Stephan Dehen et al. / Procedia CIRP 87 (2020) 95–100
4 Author name / Procedia CIRP 00 (2019) 000–000

milling strategies is larger for the worn tool, than for the new
tool. This can be explained by the influence of the larger tool
runout of the worn tool and therefore higher vibrations,
resulting in fluctuations in the cutting forces.

2.3. Passive forces

The observed passive forces of the experiments are

illustrated in Fig. 5. It is clearly visible that during down-
milling the passive forces for the new tool (a) are higher than
for the worn tool (b). This is exactly the opposite of what is
expected. Normally the enlarged radius of the end cutting edge
(see Table 2) would lead to a higher negative rake angle and

Fig. 6. Display of frequency response of the cutting force signal for the
new tool, fz = 5 µm and vc = 50 m/min.

strategy and fz = 5 µm is illustrated in Fig. 6. In the plot four

significant peaks can be observed. The first is located at 88 Hz,
the second at 177 Hz, the third at 265 Hz and the fourth at 354
Hz. With a spindle speed of 5305 min-1 and z = 4, the fourth
peak represents the impact frequency of the cutting edges
(IPF):
𝑛𝑛 ∙ 𝑧𝑧
𝐼𝐼𝐼𝐼𝐼𝐼 = (𝐻𝐻𝐻𝐻)
60

Fig. 5. Display of the passive forces, measured during the experiments.

First row: down-milling with the new (a) and worn (b) tool. Second row:
up-milling with the new (c) and worn (d) tool.

thus to ploughing and higher passive forces. The passive force

also increases with the cutting speed and the feed rate for the
new tool, while it only increases with the feed rate for the worn
tool and remains constant when the cutting speed is risen.
During the up-milling strategy, the passive forces grow with
the feed rate, but remain the same when the cutting speed is
increased. In addition, the passive forces for the new tool (c)
and the worn tool (d) are very similar. It can be noted that the
standard deviation of the passive forces of the up- and down-
milling are very much alike. This is not consistent with the
evaluation of the cutting forces. An explanation for this could
be that the sample was mounted on the dynamometer and the
x- and y-directions are in the mounting plane. By nature this
setup is stiffer in axial than transversal direction, resulting in
lower axial vibration.

2.4. Frequency analysis

The measured cutting forces were evaluated for its

frequency response, using the short time fourier transformation
(STFT). For a sampling rate of 3333 Hz, a Gaussian window
with size 1024 and an overlap of 922 was applied. Due to the
limited sampling rate, only the experiments with vc = 50 m/min,
were investigated. The STFT for the new tool, down-milling
Fig. 7. Display of evaluated peak magnitude of the frequency response
of the cutting force, measured during the experiments. First row: down-
(a) and up- (b) milling for fz = 5 µm. Second row: down- (c) and up- (d)
milling for fz = 10 µm. Third row: down- (e) and up- (f) milling for
fz = 15 µm.
 Stephan Dehen et al. / Procedia CIRP 87 (2020) 95–100
Author name / Procedia CIRP 00 (2019) 000–000
While the first peak represents the dominant frequency
rising from the spindle peed.
In the following analysis the relative magnitude for the forth
different peaks is evaluated and compared in Fig. 7. It
demonstrates that for all feed rates, the relative magnitude of
vibrations is larger for the worn tool than for the new one. That
can be caused by the larger cutting edge radii, non-uniform tool
wear and larger tool runout (see section 2.1). Also the most
dominant frequency peak is number one, caused by the spindle
rotation frequency.
The results show also that for fz = 5 µm and the new tool
produces similar vibrations for down- (a) and up- (b) milling,
while the worn tool exhibits a larger deviation in the relative
magnitude.
With fz = 10 µm and fz = 15 µm, the results look very similar
(c - f). The worn tool shows the highest vibration for the first
peak, which means for the spindle speed frequency. That could
be explained by the huge non-uniform tool-runout and unstable
tool-workpiece interactions.
2.5. Surface roughness
The surface was analyzed on an area of 160 x 1600 µm using
a confocal light microscope. To extract the surface roughness
parameters, a SL-filter with a cut-off length of λc = 0.25 mm.
The resulting surface roughness parameters are given in Fig. 8.
When down-milling (a - b), the surface roughness increases
with the feed per tooth (except at vc = 75 m/min), while the
influence of the cutting speed can be neglected. In general, the
new tool tends to produce a better surface quality than the worn
tool which was to be expected. Certain results with the new
tool, feed fz = 15 µm and cutting speed vc = 25/50 m/min, show
large standard deviations in surface roughness along one of the
grooves. In both cases, the surface topography (pictured in
Fig. 9) shows a damaged surface, which could be due to the
poor chip removal without cooling fluid or air. Cooling was not
Fig. 8. Display of the resulting surface roughness Sa, measured after the
experiments. First row: down-milling with the new (a) and worn (b)
tool. Second row: up-milling with the new (c) and worn (d) tool.
99
5
Fig. 9. Measured surface of the vc = 25 m/min, fz = 15 µm, down-
milling, new tool - sample
performed during the experiments, since the pressure would
influence the cutting force measurements.
During the up-milling (c - d) the tendencies differ strongly
from the downward milling experiments. With the new tool,
the surface quality tends to improve with increasing cutting
speed. At higher cutting speeds (50 and 100 m/min) the surface
roughness decreases with rising feed rate. When using the worn
tool, the surface quality is generally worse than with the new
tool, expect at a low feed rate of fz = 5 µm, with the worn tool
giving better results than the new tool.
3. Conclusion
The present paper deals the analysis of the influence of
cutting parameters, machining strategy and tool wear on the
surface roughness.
For this, micro-end milling experiments were conducted in
brass, with varying cutting parameters, milling strategies and
different tool wear states. The process forces were measured
in-process, while the resulting surface roughness was measured
afterwards. The forces were analyzed on their magnitude as
well as for their frequency composition, indicating how often
they cut per revolution.
The results reveal that the tool wear and the feed rate
generally increase the cutting forces, while the cutting speed
tends to decrease the cutting forces. The surface quality
behaves instable, which means that no real tendencies could be
detected. The general assumption, that high tool wear creates a
worse surface quality could not be verified. The instable
behavior was also detected by analyzing the frequency
behavior of the cutting forces.
Acknowledgements
The authors thank the DFG, the Deutsche
Forschungsgemeinschaft (German Research Foundation) for
support of the investigations within the funding
INST 121384/59.
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[4] De Oliveira FB, Rodrigues AR, Coelho RT, de Souza AF. Size effect
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