The project involved the development of simulation techniques for tool deflection and milled profile in micro and conventional end-milling processes, with an aim to improve the methods being currently employed to choose near optimum process parameters, primarily axial and radial depths of cut.

In the project, a methodology to shortlist process parameters was developed using the modeling of tool deflection and the surface error. The existing cutting force models in the micro and macro domains were compared and validated with a set of micro milling experiments.

Through the experiments, an improvement in productivity and quality over current industrial practices was demonstrated