Abstract
In this study, an approach using feed rate control was applied for improvement of form accuracy in the micro-end milling process. In this approach, called adaptive control constraint, the feed rate is controlled such that the cutting load is kept constant and deflection of the tool does not occur. However, this method is not always effective in the micro-cutting process, and the influence of the size effect cannot be ignored. Therefore, the relationships between cutting conditions and form error in micro-end milling were experimentally investigated. The experiments on the machining of metal mold steel with the micro-end mill were carried out and the formulation as a function of the cutting conditions and the form error was identified by regression analysis. The performance of the feed rate control was validated based on experimental results. The results confirmed improvement of the form accuracy.
