The International Journal of Advanced Manufacturing Technology (2020) 108:3335–3349

https://doi.org/10.1007/s00170-020-05574-6

ORIGINAL ARTICLE

Analytical modelling and experimental validation of micro-ball-end

milling forces with progressive tool flank wear
Lin Zhou 1 & Ben Deng 1 & Fangyu Peng 2 & Rong Yan 1 & MinghuiYang 1 & Hao Sun 1

Received: 10 October 2019 / Accepted: 2 June 2020 / Published online: 19 June 2020
# Springer-Verlag London Ltd., part of Springer Nature 2020

Abstract
In this paper, an analytical model for estimating the micro-ball-end milling forces is presented based on experimental investigation
of progressive tool flank wear. The wear form and wear mechanism of the micro-ball-end mill are revealed through a series of
micro-ball-end milling experiments. The effecting laws of cutting parameters such as feed per tooth, cutting speed, and inclined
angle on tool flank wear are investigated. The experimental results indicate that the progressive tool flank wear has significant
influence on cutting force in micro-milling of NAK80 steel. To assure the prediction accuracy of micro-ball-end milling force, an
analytical methodology is presented to estimate cutting forces which considers not only the shearing force resulted from chip
formation but also ploughing and rubbing force resulted by combined elastic contact and plastic flow at enlarged flank wear land.
To verify the validity of the developed analytical model, a series of experiments are carried out on high-precision machine by using
micro-ball-end mill with different flank wear lands. The comparisons of theoretical and experimental cutting forces indicate that the
developed model can provide acceptable predicted accuracy. The proposed analytical cutting force model could be employed to
monitor progressive tool flank wear land width in micro-ball-end milling of complex surface in future work.

Keywords Micro-ball-end milling . Progressive flank wear . Cutting force . Analytical model

Nomenclature θs Material separation angle

α, αe Nominal/ effective rake angle σJC Reference yield stress
αt Empirical constant σw, σ0 Normal stress
β Friction angle τw, τ0, τ Shear stress
ε, ε̇, ε̇0 Equivalent strain, strain rate, μ Friction coefficient
reference strain rate ξ Exponential constant of tool-chip
ς Ratio of lc to tc interface pressure distribution
δ Surface inclination angle ρ Material density
R0, η0, γ0, α0, and ρ0 Slip-line parameters ϕ Shear angle
κ Axial position angle A, B, C, m, n Johnson-Cook model parameters
ηc Chip velocity angle b Burgers vector
θk Position angle of cutting edge element db Projected length of cutting edge
element along cutting velocity
ds Length of the curved cutting edge
* Fangyu Peng element
zwm8917@263.net ft Feed per tooth
Fx, Fy Cutting forces in x and y direction
1
National NC System Engineering Research Center, School of
G Shear modulus
Mechanical Science and Engineering, Huazhong University of hc Undeformed chip thickness
Science and Technology, Wuhan 430074, China i Oblique angle
2
State Key Laboratory of Digital Manufacturing Equipment and Ktc, Krc, Kac Shear-specific coefficients
Technology, School of Mechanical Science and Engineering, Kte, Kre, Kae Ploughing-specific coefficients
Huazhong University of Science and Technology, Wuhan 430074, Ktw, Krw, Kaw Friction-specific coefficients
China
3336
M Taylor factor
re Cutting edge radius
r Nye factor
T0, Tm, Ts Temperatures of room, melt,
and primary shear plane
VB, VB* Flank wear land width, critical
flank wear land width
1 Introduction
Micro-ball-end milling is used as broadly as possible to pro-
duce the complex three-dimension micro-parts, for example,
micro-lens array, micro-pump, and micro-turbine, in the fields
of optics, biotechnology, and aerospace [1–4]. Among the
fundamental parameters, cutting force is one of most the crit-
ical factors in affecting the processing efficiency, as well as
the products quality. To reduce costs and improve production
efficiency and quality, it is imperative to establish a reliable
prediction model for the micro-ball-end milling process.
The previous researches provide some insight into that the
change of cutting-edge shape induced by the time-varying tool
wear, as well as build-up edge, influences on the machining
performance of the tool via affecting the cutting force in cut-
ting process. Some of the concerns about tool wear from a
macro-milling may not be effective for micro-ball-end milling
processes because of the simplification of tool geometry and
the well-known size effect, which affects the kinematics char-
acterize of micro-machining and chip formation mechanism.
Hence, study on tool wear in micro-milling of NAK80 steel
with micro-ball-end mill and accurately modelling of cutting
forces taking into account tool wear are desirable.
In recent years, some work has been conducted to study the
tool wear in micro-end milling process. Santos et al. [5] inves-
tigated the tungsten carbide micro-tool wear in micro-end mill-
ing UNS S32205 steel. The results showed that the tool wear is
in the form of nose and flank wear, and adhesion wear mecha-
nism is predominant, validated by the observation of adhered
material at the cutting edge. Ucun et al. [6] investigated the effect
of coating material on tool wear in micro-end milling of Inconel
718, and the results showed that the cutting tools coated with
AlTiN, TiAlN+AlCrN, and AlCrN displayed better perfor-
mances. Özel et al. [7] investigated the influence of CBN coat-
ing as well as cutting parameters on tool wear in micro-end
milling of Ti-6Al-4V by experiments and 2D FEM, then further
studied the impacts of tool wear on cutting forces and chip
formation by 3D FEM [8]. Vipindas et al. [9] studied the wear
characteristic of solid tungsten carbide tool with TiAlN coating
during micro-milling of Ti-6Al-4V. The tool fails after about
700-mm cut length with ft of 0.3 μm; however, tool fails after
about 1000-mm cut length with ft of 5 μm. Adhesive wear is the
major tool wear mechanism. Wang et al. [10] studied the
Ti(C7N3)-based cermet micro-tool wear mechanisms in
Int J Adv Manuf Technol (2020) 108:3335–3349
micro-end milling of Ti-6Al-4V, and the tool wear mechanisms
including the adhesive wear, chipping, oxidative wear, flank
wear, and diffusion wear, while the abrasive wear was not dis-
covered. Wu et al. [11] studied PCD micro-tool wear mecha-
nisms in micro-end milling of tungsten carbide. The results
mean that PCD tool wear is concentrated on the tool tip, and a
triangular wear belt is formed on the tool bottom surface, and the
wear mechanisms involved mainly are adhesive wear, micro-
chipping, and abrasive wear. Bai et al. [12] investigated the wear
mechanism and cutting performance of PCD tools in micro-end
milling of Ti-6Al-4V. The influence of tool geometrical param-
eters on wear resistance was discussed, and a PCD tool with rake
angle of 5°, clearance angle of 15°, tool cutting edge radius of 20
μm, and PCD granularity of 10 μm has highest cutting perfor-
mance among the tested tools. Teng et al. [13] investigated tool
wear behaviour in micro-milling of nano Mg/Ti metal matrix
composites. The results indicated that the main wear mecha-
nisms were flank wear and edge chipping due to abrasive wear
and chip adhesion in uncoated micro-end mills. Alhadeff et al.
[14] addressed that while measuring the wear of miniature end
mill, the parameters such as tool radius and edge radius should
be determined, and an improved way to measure the wear of
miniature end mill was proposed. Most of previous studies focus
on investigations of wear mechanisms in micro-end milling.
However, to date, very meager efforts have been devoted to
investigating the wear forms, mechanisms, and laws of micro-
tool in micro-ball-end milling of NAK80 steel; exactly, these
micro-machining processes are dominant in producing some
complex miniature 3D parts.
The micro-tool wear has significant influence on cutting
force [7, 8]; thus, it is very significative to predicate the
micro-ball-end milling force of NAK80 steel by taking into
account of progressive tool wear, which is helpful to increase
forecast precision. In the past decade, a lot of attentions have
been paid on development of analytical, mechanistic, and finite
element models to estimate the cutting force in micro-end mill-
ing. Waldorf et al. [15] developed a slip-line model with the
edge radius considered for the estimation of ploughing forces in
orthogonal cutting. Based on such a slip-line model, Vogler
et al. [16] proposed a new method for predicting the micro-
milling force in consideration of the ploughing effect stemmed
from edge radius, and the shear angle, prow angle, etc. in de-
veloped model were calibrated by utilizing the finite element
method. Jin and Altintas [17] further put forward a slip-line
field model by taking into consideration of the stress change
inside deformation zone which was the result of edge radius
effect. On the basis of slip-line theory and finite element simu-
lation, Zhu et al. [18] developed an analytical model for
fast/slow servo turning in view of the impacts of shearing and
ploughing effects resulted by the round edge and cutting depth.
Malekian et al. [19] presented a mechanistic model considering
the minimum chip thickness and elastic recovery effect caused
by edge radius. Afazov et al. [20] predicted the cutting forces in
Int J Adv Manuf Technol (2020) 108:3335–3349
micro-milling through the proposed mechanistic model, be-
sides, the finite element simulations of orthogonal cutting be-
came the main tool for calculating the cutting force coefficients
considering the cutting edge radius effect, and the model of
cutting forces was established considering tool wear effect.
Karpat and Oliaei [21] investigated the effect of built-up edge
and flank wear on cutting force, and the developed mechanistic
model with tool wear provided estimates to the cutting forces
during micro-milling of Stavax steel. Lu et al. [22] presented a
modified semi-analytical cutting force model considering tool
flank wear in micro-end milling of Inconel 718 with solid tung-
sten carbide tool. Recently, Zhu and Zhang [23] investigated
the relationship between macro-ball-end milling force and tool
flank wear based on a generic wear model with adjustable co-
efficients. It is shown that the prediction accuracy of instanta-
neous ball-end milling force can be improved with inclusion of
the wear factor. However, up to now, limited efforts have been
made to development of analytical methodology to estimate
micro-ball-end milling force of NAK80 steel taking into ac-
count progressive tool flank wear.
As stated above, the previous investigations contribute the
investigation of micro-tool wear mechanism and the prediction
of cutting forces during micro-end milling. However, the pro-
gressive flank wear behaviour of micro-ball-end mill and the
associated cutting force estimation in micro-milling of NAK80
steel is still very rare. The purpose of this paper is to establish an
accurate cutting forces prediction model about micro-ball-end
milling of NAK80 steel based on experimental study of pro-
gressive tool flank wear. The wear mechanism of miniature
cutter is revealed through a series of experiments, and a new
analytical model is raised to estimate the cutting forces with the
progressive flank wear. The cutting force model incorporates
not only the shearing action caused by chip formation but also
the ploughing and friction action induced by combined elastic
contact and plastic flow at progressive flank wear land.
This paper is organized as follows: In section 2, an analytical
model is proposed to predict the micro-ball-end milling forces
in consideration of tool flank wear. In section 3, the wear mech-
anism of miniature ball-end mill in micro-milling of NAK80
steel is investigated first. Then the proposed model is adopted to
estimate cutting force in micro-ball-end milling of NAK80 steel
under progressive flank wear, and the validation experiments
are carried out. In section 4, the characteristics of this proposed
model are revealed, and some conclusions can be drawn.
2 Analytical modelling of cutting forces
considering progressive flank wear
2.1 The cutting forces in micro-ball-end milling
According to Fig. 1, it can be observed that the cutting forces
acting on infinitesimal segment cutting edge Pc (k, t, κ) can be
3337
defined as elemental force component in tangential, radial,
and axial direction, i.e. dFt (k, t, κ), dFr (k, t, κ), and dFa (k,
t, κ), which considers the influences of shearing force resulted
by chip formation as well as ploughing and frictional forces
combined elastic contact and plastic flow at enlarged flank
wear land. It can be given as follows [24]:
8
< d F t ðk; t; κÞ ¼ K tc hc ðk; t; κÞdb þ K te ds þ K tw ds
d F r ðk; t; κÞ ¼ K rc hc ðk; t; κÞdb þ K re ds þ K rw ds ð1Þ
:
d F a ðk; t; κÞ ¼ K ac hc ðk; t; κÞdb þ K ae ds þ K aw ds
where k = 0,1…K-1, and K are the number of flutes. κ is the
axial position angle of cutting edge element Pw (k, t, z). ds is the
length of the curved cutting edge element, and db is the
projected length of cutting edge element along cutting velocity
direction. hc (k, t, z) is the instantaneous undeformed chip thick-
ness of cutting edge element, and the accurately calculation of
hc including the tool run-out is presented in the previous work
[25]. Ktc, Krc, and Kac are the shear-specific coefficients, Kte,
Kre, and Kae are the ploughing-specific coefficient, Ktw, Krw,
and Kaw are the friction-specific coefficients. In the present
work, not only the shearing force resulted from chip formation
but also ploughing and rubbing force induced by combined
elastic contact and plastic flow at enlarged flank wear land are
considered to determine the cutting forces coefficients.
The elemental force components in the X, Y, and Z direc-
tions can be obtained according to following equation:
0 1 0 10 1
d F x ðk; t; κÞ −coswt −sinwtsinκ −sinwtcosκ d F t ðk; t; κÞ
@ d F y ðk; t; κÞ A ¼ @ sinwt −coswtsinκ −coswtcosκ A@ d F r ðk; t; κÞ A
d F z ðk; t; κÞ 0 cosκ −sinκ d F a ðk; t; κÞ
ð2Þ
where w is spindle rotation speed (rad/s). To sum up elemental
cutting forces for all of the engaged cutting element, the
resulting cutting forces at each time t can be obtained.
2.2 Shearing force, ploughing force, and frictional
force
In this study, the shear-specific coefficients are calculated ac-
cording to classical oblique cutting model [24], and it is given
by:
τ cosðβ n −αn Þ þ tanitanηc sinβ n
K tc ¼ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
sinϕn
cos2 ðϕn þ β n −αn Þ þ tan2 ηc sin2 βn
τ sinðβ n −αn Þ
K rc ¼ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð3Þ
sinϕn cosi
cos2 ðϕn þ βn −αn Þ þ tan2 ηc sin2 βn
τ cosðβ n −αn Þtani−tanηc sinβ n
K ac ¼ qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
sinϕn
cos2 ðϕn þ β n −αn Þ þ tan2 ηc sin2 β n
where τ is the shear yield stress, αn, βn, and ϕn are the rake
angle, friction angle, and shear angle in normal plane, respec-
tively. The ηc is the chip flow angle, and i is the oblique angle.
3338 Int J Adv Manuf Technol (2020) 108:3335–3349

Fig. 1 The cutting force Z

component acting on the element
cutting edge

cutter

flank wear land

dn X rake face workpiece
workpiece shear plane
flank face dz
re
Y

ol

ip
to

ch
tc (j,t,κ) dFr

dFa

dFt X

workpiece

The chip flow angle ηc is equal to the oblique angle i approx-
imately determined by Stabler rule, and the oblique angle i is
equal to the helix angle λ.
Due to the limits of manufacturing process, the cutting
edge of micro-end mill cannot be deemed as perfect sharp.
As instantaneous undeformed chip thickness decreases to near
to the edge radius, the ploughing action would prevail over
shearing action. In this work, the slip-line field theory model
with stable built-up edge developed by Waldorf et al. [15]
shown in Fig. 2 is utilized to estimate the ploughing-specific
coefficients, which could be expressed by:

8
>
> τ ðcosð2η0 Þcosðϕn −γ 0 þ η0 Þ þ ð1 þ 2α0 þ 2γ 0 þ sinð2η0 ÞÞsinðϕn −γ 0 þ η0 ÞÞR0
>
> K ¼
< te sinη0
τ ðð1 þ 2α0 þ 2γ 0 þ sinð2η0 ÞÞsinðϕn −γ 0 þ η0 Þ−cosð2η0 Þcosðϕn −γ 0 þ η0 ÞÞR0 ð4Þ
>
> K re ¼
>
> sinη0
:
K ae ¼ K te sini

where R0, η0, γ0, α0, and ρ0 are the slip-line field parame- where τw and σw are the shear and normal stress acting on the
ters. Details for computing those values are available in [15]. flank wear land, and it can be calculated by:
In addition, according to the investigations carried out in
section 3.1, it can be found that the flank wear is the main wear Case one VB < VB*
form in micro-milling of NAK80 steel during the setting test  2
condition, and flank wear land width is usually in the range of VB−x
σw ð xÞ ¼ σ0 0 < x < VB ð6Þ
a few microns to a few tens of microns, which is close to or VB
even larger than instantaneous undeformed chip thickness of 8  pffiffiffiffiffiffiffiffiffiffiffiffi
< τ0 0 < x < VB 1− τ 0 =σ0
cutting edge element, and hence the ploughing and rubbing τ w ð xÞ ¼  pffiffiffiffiffiffiffiffiffiffiffiffi ð7Þ
forces induced by combined elastic contact and plastic flow at : μ σw ð xÞ VB 1− τ 0 =σ0 < x < VB
w
enlarged flank wear land are very significant compared with
that in macro-ball-end milling. To improve estimation accura-
cy in micro-ball-end milling of inclined surface, it is essential Case two VB > VB*
to model the cutting force considering progressive flank wear. 8
<  σ0  0 < x < VB−VB
*
The frictional force coefficients related to the enlarged flank σw ð xÞ ¼ VB−x 2
ð8Þ
wear land are given as: : σ0 VB−VB* < x < VB
8 VB*
> VB
< K tw ¼ ∫0 τ w ðxÞ dx  pffiffiffiffiffiffiffiffiffiffiffiffi
VB
K ¼ ∫0 σw ðxÞ dx ð5Þ τ0 0 < x < VB−VB
p
*
ffiffiffiffiffiffiffiffiffiffiffiffi τ 0 =σ0
>
: rw τ w ð xÞ ¼ ð9Þ
K aw ¼ K tw sini μw σw ðxÞ VB−VB τ 0 =σ0 < x < VB
*
Int J Adv Manuf Technol (2020) 108:3335–3349 3339

2.3 Estimation of model parameters

As the instantaneous undeformed chip thickness is near to or

less than the edge radius, the chip forms nearby the cutting
edge, experiencing large negative rake angle. In this paper, the
average rake angle model is introduced to calculate effective
rake angle αe, it can be given by [16]:
8 0 v ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 1
> u  ςh 
>
> u
>
> B u 2− ςh C
>
> B t re C
>
> B −sinθ f C
>
> B re C
>
> arctanB Cðh=re ≤ 1 þ sinαÞ
Fig. 2 Slip-line field theory model by Waldorf et al. >
>
> B− ςh C
>
< B −1 þ cosθ C
B f C
αe ¼ @ re A
>
>
where VB* is the critical flank wear land width. Tool- >
>
>
> 0  1
workpiece contact results in significant plastic flow of work- >
> ςh
>
> −1 tanα−secα þ sinθ f  
>
> B re C h
piece material beneath the worn flank face when VB is larger >
> arctanB C > 1 þ sinα
>
> @ ςh A re
than VB*. VB* has been approximately determined as 21 μm >
: −1 þ cosθ f
re
by the measured cutting forces in section 3.1. τ0 and σ0 are the
shear and normal stress at the cutting edge, it can be calculated ð12Þ
by:
where θf is the separation angle, and it is considered
σ0 ¼ τ ð1 þ 2α0 þ 2γ 0 þ sinð2η0 ÞÞ ð10Þ as 37.6°, and ς is constant taken as 2 in the present
work.
τ 0 ¼ τcosð2η0 Þ ð11Þ
According to the momentum equilibrium analysis of chip,
the normal friction angle βn can be derivated as follows [26]:

  ! !
ξ þ 2 sin2ðϕn þ βn −αn Þ ξ þ 2 sin2ðϕn þ βn −αn Þ 1=ξ
tanβ n ¼ ξ 1− þ1 ð13Þ
4ð ξ þ 1 Þ cos2 βn 4μðξ þ 1Þ cos2 βn

where ξ is the exponential constant, and it represents the
pressure distribution regarded as 3. μ is the sliding friction
coefficient at interface between tool and chip, taken as 0.6.
The shear angle in orthogonal cutting could be assumed to
be equal to the normal shear angle ϕn in oblique cutting, and
hence the shear angle equation developed by Merchant is uti-
lized to calculate ϕn in this work:
ϕn ¼ C 1 −C 2 ðβn −αn Þ
where C1 is constant chosen as 0.785, and C2 is selected
as 0.5. Substituting Eq. (12) and Eq. (14) into Eq. (13)
and rearranging the terms, the βn can be figured out.
Then, substituting αn and βn into Eq. (14), the ϕn can
be obtained.
The shear yield stress is estimated according to a mod-
ified Johnson-Cook constitutive model, which including
the strain-hardening, strain-rate, temperature, and the
strain gradient plastic strengthening. It can be expressed
ð14Þ by [27]:

!! vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
!uffi
 m u
u
1 ε̇ T −T r t1 þ M rαt G bðsinϕn =hÞ
2 2 2
τ¼ ðA þ BðεÞn Þ 1 þ Cln 1− ð15Þ
M ε̇0 T m −T r σ2JC

where A, B, C, m, and n are material Johnson-Cook consti- temperature, and Tr is the room temperature. M is Taylor fac-
tutive model constants. ε and ε̇ are the equivalent plastic strain tor, b is the Burgers vector, G is the shear modulus, r is Nye
and strain-rate, respectively, ε̇0 is reference plastic strain-rate. factor, and αt and u are the empirical coefficient and exponen-
T is the material temperature, Tm is the material melting tial factor, respectively.
3340 Int J Adv Manuf Technol (2020) 108:3335–3349

Micro ball-end mill

(EBM R0.5*2C TiALN)

Dynamoter&Charge
(Kistler9119AA1、5080A)

tion
direc
Feed

20º terval
Path in

Up-ramping in down-cutting
Ultra-precision machine
（UPM350）
NI data
acquisition system

Fig. 3 The set-up of micro-milling of inclined surface on high-precision machine

3 Experimental validation of micro-ball-end Fig. 4, according to the test 4 listed in Table 1. It can be
milling forces with progressive flank wear observed that the cutting force amplitude in X-direction in-
creases nearly 100% as the VB rises from 0 to 25 μm, and
3.1 Investigation of tool wear in micro-milling cutting force amplitude in Y-direction increases nearly 150%.
The stiffness of micro-ball-end mill is relatively low due to its
The micro-milling tests are performed on high-precision ma- small diameter, and the large cutting force induced by tool
chine tool, and it has excellent repetitive positioning accuracy flank wear would easily leads to tool deflection, vibration,
of 100 nm, as well as the radial run-out smaller than 30 nm, as and failure. Thus, to improve prediction accuracy of micro-
shown in Fig. 3. The solid carbide micro-ball-end mill with ball-end milling force, the development of analytical model
two flutes (EBM2 R0.5*2C TIALN) is used, which has diam- taking into account progressive tool flank wear is necessary.
eter and nominal helix angle of 1 mm and 30°, respectively. Besides, it can be noticed that the cutting force amplitude
The workpiece material of NAK80 steel has a hardness of 42 increases nonlinearly with increasing flank wear land width
HRC. The edge radius is 1.2 μm and the rake angle is 8°. The VB, and the slope is almost piecewise linear. The cutting force
spindle speed is 10,000, 30,000, 40,000, and 60,000 rpm, amplitude increases relatively gently with increasing VB when
respectively. The inclined angle of workpiece is 10°, 20°,
30°, and 40°, respectively. The cutting mode is selected as
up-ramping in down-cutting, and it may be one of the one Table 1 Experimental conditions for investigation of tool wear
most favorable cutting modes compared with other represen- Test ft (μm) n (r/min) δ (deg) Cutting strategies
tative cutting strategies, such as down-ramping in up-cutting,
up-contouring in up-cutting, and down-contouring in down- 1 0.9 40,000 20 Up-ramping in down cutting
cutting that reported by Fontaine et al. [28]. The preliminary 2 2.5 40,000 20 Up-ramping in down cutting
investigation of influence of aforementioned representative 3 4.5 40,000 20 Up-ramping in down cutting
cutting strategies on cutting force in micro-milling of 4 6 40,000 20 Up-ramping in down cutting
NAK80 steel is available in section 3.3. The cutting depth is 5 6 10,000 20 Up-ramping in down cutting
100 μm, and the interval is 500 μm, namely slot milling. The 6 6 30,000 20 Up-ramping in down cutting
test conditions in detail are listed in Table 1. 7 6 60,000 20 Up-ramping in down cutting
The cutting forces are measured by the dynamometer 8 6 40,000 10 Up-ramping in down cutting
(Kistler 9119AA1) and the charge amplifier (5080A). The 9 6 40,000 30 Up-ramping in down cutting
relationship between the cutting forces and tool flank wear 10 6 40,000 40 Up-ramping in down cutting
in micro-ball-end milling of inclined surface is shown in
Int J Adv Manuf Technol (2020) 108:3335–3349 3341

20
roughness especially when VB is over VB*. The processed
Cutting Forces Amplitude (N)
Fx surface roughness is up to 0.18 μm when the flank wear width
16 Fy VB reaches 30 μm. This phenomenon may be explained with
that the ploughing and rubbing effect located at flank face
nearby cutting edge enhance with an increasing VB, which
12
lead to increasing of micro-chipping of cutting edge and vi-
bration of micro-ball-end mill, and hence it gives rise to an
8 increasing of surface roughness.

4
3.1.1 The wear form and mechanism in micro-ball-end milling
of NAK80 steel

0 The wear forms of micro-ball-end mill are determined by the

0 10
Flank wear land width VB ( m)
Fig. 4 The relationship between cutting forces and progressive flank
wear (test 4 listed in Table 1)
VB is less than critical flank wear width VB*, and then the
cutting force amplitude increases quickly with an increase of
VB. This is because only elastic contact exists on the flank face
when VB is less than VB*, while plastic flow begins to occur on
flank face nearby cutting edge with an increasing VB due to the
increasing thermal mechanical load. The VB* may be approx-
imately regarded as 21 μm according to Fig. 4; however, it is
far less than that reported in macro-ball-end milling [23, 29].
The relationship between the surface roughness and tool
flank wear in micro-ball-end milling of inclined surface is
shown in Fig. 5, according to the test 4 listed in Table 1.
The surface roughness is measured by Talysurf PGI 830
Taylor-Hobson surface profiler. It can be found that the ma-
chined surface roughness firstly declines slightly with the in-
crease of VB, and then surface roughness rises quickly with an
increasing VB. This indicates that moderate tool flank wear is
conducive to the finishing surface and reducing roughness;
however, excessive wear notably deteriorates surface
0.18
Surface roughness Ra ( m)
20 30
FIB (Helios G3CX) shown in Fig. 6. It can be observed that
the flank wear is the main wear form. The main wear mecha-
nisms of cutting edge are adhesive wear; however, the other
wear patterns, such as chipping, build-up edge, diffusive wear,
and coating falling off, are not significant during the setting
test condition. Besides, the adhered workpiece material was
found at the cutting edge, rake face, and flank face, indicating
the occurrence of the adhesion wear mechanism.
The EDS analysis is carried out to determine whether the
workpiece material was adhered to the micro-ball-end mill.
Figure 7 shows the EDS analysis performed on the worn flank
face of micro-ball-end mill. The elements of the workpiece
material (chromium, iron, manganese, silicon) are adhered to
the worn flank face of micro-ball-end mill. The weight of
coatings elements (titanium and nitrogen) decline sharply,
and the substrate elements of micro-ball-end mill (cobalt)
were observed, indicating the coating wear. In addition, the
oxidation of adhered workpiece material at worn flank face
may be explained by the higher temperature generated in flank
wear land due to serious elastic contact actions and plastic
flow.
3.1.2 The influence of machining parameters on progressive
flank wear
The feed per tooth The effect of feed per tooth on flank wear

0.16 in micro-milling of NAK80 steel is described in Fig. 8, ac-

cording to the tests 1–4 listed in Table 1. The cutting length
0.14 associated with the flank wear width coming up to 30 μm is
defined as the maximum cutting length. It can be observed
0.12
that the maximum cutting length increases with the increase
0.10 of feed per tooth, especially for the case that feed per tooth is
bigger than edge radius, such as test 3 and test 4. Meanwhile, it
0.08 can be noticed that wear rate is obviously different under the
different feed per tooth, and the wear rate increases with the
0.06
decrease of feed per tooth, especially for the case that feed per
0 5 10 15 20 25 30 tooth is close to the edge radius, such as test 1 and test 2. The
Flank wear land width VB ( m) influence of feed per tooth on tool wear in micro-ball-end
Fig. 5 The relationship between surface roughness and tool flank wear milling is obviously different from that namely the wear rate
(test 4 listed in Table 1) rising with the increase of feed per tooth in macro-ball-end
3342 Int J Adv Manuf Technol (2020) 108:3335–3349

(a) (b) New cutter

(c) Worn cutter

Flank wear

Adhensive wear

Fig. 6 SEM analysis of cutting edge of micro-ball-end mill. a Experimental setup. b New cutting edge. c. Worn cutting edge

milling. The size effect resulted from the ploughing action and hc ðk; t; κÞ ¼ f t sinθk sinκ ð16Þ
strain gradient plasticity effect could be employed to explain
aforementioned phenomenon. The undeformed chip thickness where θ k is position angle, θ k = wt − (k − 1)2π/N − (1 −
can be approximately calculated by: cos(κ)) tan(λ), and κ is axial position angle. For test 1 and test

(a) New cutter

NK 18.19%
TiK 46.35%
AlK 25.54%
OK 5.78%
CrK 4.14%

(b) Worn cutter

OK 31.55%
AlK 27.85%
SiK 0.95%
Co K 0.59%
TiK 13.04%
CrK 11.97%
M nK 1.09%
FeK 9.12%

Fig. 7 EDS of flank face of micro-ball-end mill. a New cutting edge. b Worn cutting edge
Int J Adv Manuf Technol (2020) 108:3335–3349 3343

(a) (a)
30 30

25 25

20
VB( m)

20

VB( m)
15 fz=0.9 m 15
10 fz=2.5 m V=31.4m/min
10
fz=4.5 m V=94.2m/min
5
fz=6 m 5 V=125.6m/min
0 V=188.4m/min
0 2000 4000 6000 8000 10000 0
Cutting Length(mm) 0 2000 4000 6000 8000 10000 12000
Cutting Length(mm)
(b)
14000

12000 (b)
Max Cutting Length( mm)

14000
10000
12000
Max Cutting Length( mm)
8000
10000
6000
8000
4000
6000
2000

0 4000
0 1 2 3 4 5 6
fz( m) 2000
Fig. 8 a, b The influence of feed per tooth on tool wear (tests 1–4 listed in 0
Table 1) 0 40 80 120 160 200
V(m/min)
Fig. 9 a, b The influence of spindle rotation speed on tool wear (tests 4–7
2, the undeformed chip thickness is less than edge radius. The listed in Table 1)
ploughing effect is predominant rather than shearing effect as
the instantaneous undeformed chip thickness is smaller than
the edge radius, besides the material flow stress increase with
the decrease of undeformed chip thickness due to the strain
gradient plasticity effect. Thus, the micro-tool wear rate re- 500
markably increases under such experimental condition. In ad-
Temperature of primary shear zone

dition, the WC grains at the cutting edges are weakly bonded

with cobalt binder. When the undeformed chip thickness is 400
much less than the grain size, the ploughing action causes the
WC grains to be detached from the matrix of cobalt.
300
Model ExpDec1

The cutting speed The influence of spindle rotation speed on Equation

y = A1*exp(-x/t1) + y0

Reduced Chi-Sqr 59.26523

flank wear in micro-milling of NAK80 steel is shown in Fig. Adj. R-Square 0.99094

200
Value Standard Error
y0 432.3637 21.53454
9, according to the tests 4–7 listed in Table 1. It can be found B
A1
t1
-367.34502
27502.58901
15.67876
4991.33853

that maximum cutting length changes nonlinearly with the k

tau
3.63602E-5
19063.34203
6.59887E-6
3459.73223

increase of spindle rotation speed. The maximum cutting 100

length firstly increases with rising spindle rotation speed as 0 10000 20000 30000 40000 50000 60000 70000
it is less than 30,000 rpm, then the maximum cutting length Spindle rotation speed (rpm)
decreases with the rise of spindle rotation speed as it varies Fig. 10 The temperature at primary shear zone versus different spindle
from 30,000 to 60,000 rpm. In other words, the tool wear rate rotation speed
3344 Int J Adv Manuf Technol (2020) 108:3335–3349

14000
and worsen tool wear; thus, associated maximum cutting
12000 length reduces.
Max Cutting Length (mm)

The temperature at primary shear zone in micro-orthogonal

10000
8000
6000
4000
2000
0 as the spindle rotation speed continues to increase from
10 15 20 25 30
Inclined angle (deg)
Fig. 11 The influence of surface inclination angle on tool wear (test 4,
tests 8–10 listed in Table 1)
is different as spindle rotation speed changes from 10,000 to
60,000 rpm. The influence of spindle rotation speed on tool
wear in micro-ball-end milling is different from that in macro-
ball-end milling. The low cutting speed related to low spindle
rotation speed leads to the low cutting temperature, which is
difficult to soften the workpiece material, thus accelerate the
tool wear. Then the cutting temperature rises with the increase
of cutting speed, and it enhances material softening effect and
reduces the cutting load, and hence reduces tool wear rate and
extends maximum cutting length. However, as the cutting
speed continues to increase from 30,000 to 60,000 rpm, the
cutting temperature has already gone up to the critical point,
which might damage the coating of cemented carbide tools
cutting (hc = 6 μm) obtained by finite element method (Third
Wave AdvantEdge V7.1). As shown in Fig. 2, it can be ob-
served that the temperature changes from 174 to 398 °C, as the
spindle rotation speed rises from 10,000 to 60,000 rpm. It can
be observed that the temperature at primary shear zone rises
nonlinearly with increasing spindle rotation speed. The tem-
perature at primary shear zone rises sharply as the spindle
rotation speed is less than 30,000 rpm, while it rises slightly
35 40 30,000 to 60,000 rpm. The temperature at primary shear zone
corresponding to the inflection point (about30,000 rpm) of the
curve in Fig. 10 is 308 °C.
The inclined angle The relationship between the inclined an-
gle and tool flank wear land width in micro-milling of NAK80
steel is depicted in Fig. 11, according to test 4 and tests 8–10
listed in Table 1. It can be noticed that maximum cutting
length increases linearly with the increasing surface inclina-
tion angle, and the maximum cutting length increases from
about 8000 to about 10,000 mm as the inclined angle increases
from 10 to 40°. This is because the instantaneous undeformed
chip thickness of the engaged cutting edge element increases
with increasing inclined angle; thus, the ploughing effect is
weakened while the shearing effect is enhanced, giving rise to
a reduction of wear rate. However, the variation of the maxi-
mum cutting length is not very conspicuous, and it may be
explained with the fact that the instantaneous undeformed chip

Table 2 Material physical properties of NAK80 steel

A (MPa) B (MPa) C m n ρm (kg/m3) Tm(°C) Cp(J/kg/°C) E (GPa) b (nm) αt u

949.6 716.8 0.0137 0.997 0.261 7860 1460 420 207 0.304 0.85 0.6

Table 3 Experimental parameters

for validation of micro-ball-end Test VB (μm) ft (μm) n (r/min) ap (μm) δ (deg) Cutting strategies
milling force
1 0 6 20,000 50 20 Up-ramping in down cutting
2 5 6 20,000 50 20 Up-ramping in down cutting
3 9 6 20,000 50 20 Up-ramping in down cutting
4 13 6 20,000 50 20 Up-ramping in down cutting
5 21 6 20,000 50 20 Up-ramping in down cutting
6 25 6 20,000 50 20 Up-ramping in down cutting
7 0 10 20,000 50 20 Up-ramping in down cutting
8 5 10 20,000 50 20 Up-ramping in down cutting
9 9 10 20,000 50 20 Up-ramping in down cutting
10 13 10 20,000 50 20 Up-ramping in down cutting
11 21 10 20,000 50 20 Up-ramping in down cutting
12 25 10 20,000 50 20 Up-ramping in down cutting
Int J Adv Manuf Technol (2020) 108:3335–3349 3345

thickness of the engaged cutting edge element is larger than
edge radius under the given experimental condition that ft is 6
μm.
3.2 Validation of cutting force with progressive tool
flank wear
To verify the availability of the developed cutting force mod-
el, the micro-slot milling of inclined surface with ball-end mill
is performed on the high-precision machine tool, shown in
Fig. 3. The two-flute solid carbide micro-ball-end mill
(EBM2 R0.5*2C TIALN) with progressive flank wear land
width (5 μm, 9 μm, 13 μm, 21 μm, and 25 μm) is used to mill
the NAK80 steel, and the material physical properties of
NAK80 steel are listed in Table 2. The surface inclination
angle of workpiece is 20 deg, spindle speed is chosen as
20,000 rpm, the normal depth of cut is selected to be 50 μm,
the feed per tooth ft is chosen to be 6 μm and 10 μm, and the
cutting mode is selected as up-ramping in down-cutting. To
stabilize micro-milling process and remain unchanged flank
wear land at each test, the cutting length for each test listed in
Table 3 is chosen as 30 mm and 50 mm for ft = 6 μm and ft =
10 μm, respectively. The Kistler dynamometer of 9119AA1
and charge amplifier of 5080A are introduced to obtain tiny
cutting force signal with higher sensitivity of 26pC/N, and the
cutting forces data are collected and recorded by NI data ac-
quisition system. The test condition in detail is listed in
Table 3.
The developed cutting forces model is utilized to calculate
the cutting force in micro-milling of inclined surface for the

Fx_measured Fy_measured Fx_predicted Fy_predicted

(a) (d)
10 10
8 8
6
Cutting Forces(N)

Cutting Forces( N) 6
4 4
2 2
0 0
-2 -2
-4 -4
-6 -6
0 180 360 540 720 0 180 360 540 720
Rotation Angle(deg) Rotation Angle(deg)

(b) (e)
10 10
8 8
6
Cutiing Forces(N)

6
Cutting Forces(N)

4 4
2 2
0 0
-2 -2
-4 -4
-6 -6
0 180 360 540 720 0 180 360 540 720
Rotation Angle(deg) Rotation Angle(deg)

(c) (f)
10 10
8 8
6
Cutting Forces(N)

Cutting Forces( N)

6
4 4
2 2
0 0
-2 -2
-4 -4
-6 -6
0 180 360 540 720 0 180 360 540 720
Rotation Angle(deg) Rotation Angle(deg)
Fig. 12 Comparisons of theoretical and experimental cutting forces. a Test 1. b Test 2. c Test 3. d Test 4. e Test 5. f Test 6
3346
tests 1–12 listed in Table 3. The predicted cutting forces by the
developed model are match well with the experimental cutting
forces for each case. Figure 12 shows six micro-ball-end mill-
ing cases, and it can be observed that the theoretical and ex-
perimental cutting force curves show the similar amplitude
and trend in X- and Y-direction. The phase difference between
the predicted and measured cutting force maybe related to the
dynamic of miniature cutter, the uniformity of workpiece ma-
terial, and the measuring uncertainties and so on.
Figure 13 compares the predicted average cutting force
amplitude with the measured results for all of tests. It can be
found that developed cutting force model provides acceptable
forecasting accuracy, i.e. average absolute error below 12%
considering tool flank wear both in X-direction and
Y-direction. It can be noticed that the average cutting force
amplitude segmented increases with the growth of flank wear
width, the inflection point is associated with critical flank wear
width, and the growth rate significantly rises as the VB more
than VB*. The cutting force amplitude in X-direction increases
nearly 100% as the VB rises from 0 to 25 μm, while cutting
force amplitude in Y-direction increases nearly 150% as the
VB rises from 0 to 25 μm. This phenomenon may be due to the
fact that the normal stress at worn flank face is bigger than
shear stress, especially for the case of occurring elastic contact
between worn flank face and workpiece. Therefore, to assure
(a)
10
Fx-measured
Cutting Force s Am plitude( N)
8 Fy-measured
Fx-predicted
Fy-predicted
6
4
2 amplitude in Y-direction reduces continuously with the in-
0 cutting (Fig. 14d), the average cutting force amplitude in
0 5 10 15
VB ( m)
(b)
10
Fx-measured
Cutting Forces Amplitude( N)
8 Fy-measured
Fx-predicted
Fy-predicted
6 According to the predicted and measured results shown in
4 maybe the one of most favorable cutting modes. For one
2 tion of cutting forces on the cutting edges in X- and
0 another thing, in up-ramping in down-cutting, the tool tip is
0 5 10 15
VB ( m)
Fig. 13 Comparisons of theoretical and experimental cutting forces
amplitude for all of cases. a Tests 1–6. b Tests 7–12
Int J Adv Manuf Technol (2020) 108:3335–3349
the prediction accuracy of micro-ball-end milling forces,
modelling of cutting forces considering tool flank wear effect
is essential. In addition, according to such an analytical cutting
force model, the tool flank wear land during each wear stage
can be determined by using experimental cutting force data
[30], and it can be employed to monitor time-varying tool
flank wear in micro-milling of complex surface parts with
small ball-end mill in future work.
3.3 Preliminary investigation of the representative
cutting strategies on cutting force
In order to further investigation of the representative cutting
mode and inclination angle on cutting force, simulations and
validations of micro-slot milling of inclined surface under the
four representative cutting strategies [28] (up-ramping in
down-cutting, down-ramping in up-cutting, up-contouring in
up-cutting, and down-contouring in down-cutting) as well as
different surface inclination angles are carried out. Figure 14
shows the plots of the average cutting force amplitude versus
inclination angle under aforementioned four cutting strategies.
In up-ramping in down-cutting (Fig. 14a), the average cut-
ting force amplitude varies slightly with the increasing incli-
nation angle in X- and Y-direction. In down-ramping in up-
cutting (Fig. 14b), the average cutting force amplitude de-
creases quickly with the increasing inclination angle and
reaches the minimum at inclination angle of 20° in X- and
Y-direction, and then increases as inclination angle is less than
40° and finally decreases slightly with the increasing inclina-
tion angle. In up-contouring in up-cutting (Fig. 14c), the av-
erage cutting force amplitude in X-direction rises quickly with
the increasing inclination angle and reaches the maximum at
inclination angle of 40°, and then declines slightly with the
increasing inclination angle, while the average cutting force
creasing inclination angle. In down-contouring in down-
20 25
X-direction increases with the increasing inclination angle as
inclination angle is less than 30° and then varies slightly with
the increasing inclination angle. However, the average cutting
force amplitude in Y-direction varies slightly with the increas-
ing inclination angle as inclination angle is less than 30° and
then reduces with the increasing inclination angle.
Fig. 14, it can be noticed that up-ramping in down-cutting
thing, up-ramping in down-cutting provides a better reparti-
Y-direction, which is helpful to reduce tool deflections. For
20 25
out of the cutting area, the ploughing effect is weakened and
indenting effect disappears, which is conducive to improve
workpiece surface quality. The similar results have already
Int J Adv Manuf Technol (2020) 108:3335–3349 3347

(a) (b)

Cutting Force s Amplitude(N)

6 6

Cutting Forces Amplitude(N)

Fx-m easured
Fx-measured
Fx-predicted
Fx-predicted
4 4

2 2

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Inclination angle(deg) Inclination angle(deg)
6 6
Cutting Forces Amplitude(N)

Cutting Forces Amplitude(N)

Fy-m easured Fy-measured
4 Fy-predicted 4 Fy-predicted

2 2

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Inclination angle(deg) Inclination angle(deg)

(c) (d)
Cutting For ces Amplitude(N)
Cutting Forces Amplitude(N)

6 6
Fx-m easured Fx-measured
Fx-predicted Fx-predicted
4 4

2 2

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Inclination angle(deg) Inclination angle(deg)
Cutting Forces Amplitude(N)

6 6
Cutting Forces Amplitude(N)

Fy-measured Fy-measured
Fy-predicted Fy-predicted
4 4

2 2

0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Inclination angle(deg) Inclination angle(deg)
Fig. 14 The influences of cutting strategies on milling forces. a Up-ramping in down-cutting. b Down-ramping in up-cutting. c Up-contouring in up-
cutting. d Down-contouring in down-cutting. (Machined condition: SECO 113L006-MEGA-64-T, n = 20,000 rpm, ap = 50 μm, re = 1.5 μm, ft = 6 μm)

been reported by Fontaine et al. [28] in macro-milling of in-
clined surface with aforementioned four representative cutting
strategies.
4 Conclusions
This paper presents an analytical model to predict the micro-
ball-end milling forces on the basis of experimental study of
progressive tool flank wear. Firstly, the tool flank wear mech-
anisms are studied by a series of micro-milling of inclined
surface tests on NAK80 steel with small ball-end mill. The
main wear form of miniature tool presented by micro-ball-end
milling experiments is tool flank wear, and the main wear
mechanisms of cutting edge are adhesive wear; however, the
other wear patterns, such as chipping, build-up edge, diffusive
wear, and coating falling off, are not significant during the
setting test condition. The influence of test condition on tool
flank wear is also analyzed, and some conclusions are given as
follows:
a. Due to ploughing effect, the smaller feed per tooth leads to
the more serious tool flank wear and shorter cutting
length, particularly for the situation that feed per tooth is
less than or near to edge radius, and it is different from
macro-ball-end milling. On the premise of ensuring the
3348
processing quality, appropriately increase of the feed per
tooth can reduce flank wear and improve processing
efficiency.
b. The maximum cutting length first increases and then de-
creases with the gradual rising of spindle rotation speed in
micro-ball-end milling of inclined surface due to the cut-
ting thermal effect, as a result that the optimal spindle
rotation speed for alleviating tool flank wear is existent,
nearby 30,000 rpm under the setting test condition.
c. The maximum cutting length increases linearly with the
increase of inclined angle. This is because the instanta-
neous undeformed chip thickness of the engaged cutting
edge element increases with increasing inclined angle;
thus, the ploughing effect is weakened while the shearing
effect is enhanced, giving rise to a reduction of wear rate.
Besides, the influence of tool flank wear on cutting force in
micro-ball-end milling of inclined surface is also investigated.
The average cutting force amplitude increases over 100% as
the flank wear width VB increases to about 25 μm under the
given experimental condition. The growth rate is piecewise,
and the inflection point is in connection with the critical flank
wear width VB*. The effect of tool flank wear on cutting force
is significant and complicated. To assure the prediction accu-
racy of micro-ball-end milling forces with progressive flank
wear, an analytical methodology is proposed to calculate cut-
ting force which considers not only the shearing force resulted
from chip formation but also the ploughing and rubbing action
induced by combined elastic contact and plastic flow at en-
larged flank wear land. The theoretical and experimental cut-
ting forces indicate that the prediction error is below 12% in
both X-direction and Y-direction, and the prediction accuracy
is acceptable.
Finally, according to the developed analytical micro-ball-
end milling force model, the tool flank wear land during each
wear stage can be determined by using experimental cutting
force data, and it can be employed to monitor time-varying
tool flank wear during micro-milling of complex surface parts
in future work.
Funding information This work was financially supported by the
National Natural Science Foundation of China (Grant Nos. 51805191,
51625502) and the National Key Research and Development Program of
China (Grant Nos. 2018YFB1701904).
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