Nowadays, emerging more advanced computer systems made it possible to simulate and model complex problems even with higher accuracy. Regarding lower time and cost, the use of simulations instead of physical experiments is increasingly considered as an alternative method in the analysis and optimization of process performance. The importance of such methods becomes more significant when talking about micro-processes, since there are lots of difficulties in experimental measurements as a results of scaling problems by scaling down from macro to micro. In this study, a 3D model is developed using Deform-3D software for prediction of micromilling process behavior. Effects of cutting parameters on such characteristics as cutting forces, temperature distribution and tool wear are investigated. To check the validity of the model, force results of simulation are compared with the measured ones. A high level of correlation exists between the obtained simulation and measured results which shows that the 3D developed model has good capability to predict process behavior.

Keywords: Micromilling, Simulation, cutting force, temperature, Tool wear, Titanium alloy

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