This paper presents the prediction of micro-milling forces using the finite element method (FE). An FE model of orthogonal micro-cutting with round cutting edge is developed. The cutting force coefficients are identified from a series of FE simulations at a range of cutting edge radii and chip loads. The identified cutting force coefficients are used to simulate micro-milling forces. The simulation results are experimentally validated in cutting tests with a 200 urn diameter helical end micro-mill.
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