This paper presented an experimental study on micromilling of OFHC copper using tungsten carbide micro-endmills. The following conclusions are drawn from this work; 1. The micromachining forces exhibit erratic behavior at feed rates less than the cutting edge radius. With increased feed rate, the forces resemble those from a conventional milling process. 2. At small feed rates, the magnitude of the surface roughness is much higher than that calculated from the process geometry due to the effects of ploughing and minimum chip thickness. The geometrically induced surface roughness become more dominant as the feed rate is increased. 3. Contrary to the experience from conventional milling, the largest wear in micromilling was observed for the lowest speed and the lowest feed rate, and the lowest wear was experienced at the highest speed and highest feed rate. The main mechanism of wear at low feed rates was seen to be the attrition wear.
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