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The study of micromilling of quenched and tempered AISI D2 steel is of utmost importance due to the accelerated wear of the micromilling cutting tool edge that intensifies the formation of top burrs, which is detrimental to the micromilled surfaces because requires further surface finishing. In this work, the effect of tooth feed per tooth and depth of cut on machining forces and top burr formation after dry micromilling of slots in quenched and tempered AISI D2 steel was evaluated. The results show that the passive force is approximately 32% higher than the radial and feed forces. Regarding burr formation, axial depth of cut was the most relevant parameter. Doubling depth of cut burr height increased by approximately 400%. Increasing feed per tooth reduces burr formation. The down cutting direction presented top burr heights approximately 23% higher when compared with up cutting. Abrasion and adhesion were the predominant tool wear mechanisms. Tool wear increases progressively with machining length raising the milling force components. which leads to rounding and increase the radius of the cutting edge. Consequently, a negative rake angle is generated, inducing size effect and intensifying the material ploughing mechanism.

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