Prediction of micro milling force and surface roughness considering size-dependent vibration of micro-end mill

When the characteristic structure size of component is at micron level, internal crystal grains, grain boundaries, and pore defects material with same level cannot be ignored, so micro-sized will show different physical properties from macro-sized component, which called effect. Since tool diameter a micro-end mill in also significant effect phenomenon. In addition, micro milling process, because surface roughness that affects performance service life parts mainly influenced by vibration mill, order to enhance machined quality, it crucial research formation mechanism topography process. this paper, comprehensive method proposed predict vibration, force, roughness. At first, size-dependent dynamic model presented based on strain gradient elasticity theory (SGET). Secondly, considering feedback force solved through iterative method. Then simulated actual cutting edge trajectory elastic recovery. The results increase verify accuracy efficiency method, experiments are performed, found predicted consistent experimental results.