Micromilling mechanism studies are the fundamentals for high-quality micro components fabrications. Based on the finite element method (FEM), the simulation model for micromilling of the oxygen-free copper (OFC) was established in this paper. The influences of the key process parameters (feed engagement f z , axial depth of cut a p , radial depth of cut a e , and spindle speed n) on the milling forces were investigated. According to the simulation results, to achieve the minimum undeformed chip thickness, the critical feed engagement was identified to be 2.5 μm/z. when the axial depth of cut increased, the milling force was increasing linearly, but at the same time the milling force took an oscillator decreases due to the increasing of spindle speed. The overall trend of milling force under different radial depths of cut is upward. Therefore, the feed engagement should be greater than 2.5μm/z for micro milling of oxygen-free copper. Small radial depth of cut, small axial depth of cut, and appropriate spindle speed should be selected to obtain a high machining quality.

Polyetheretherketone (PEEK) material has attracted extensive attentions and research in the medical field due to its properties similar to biological bones. But there is a lack of cutting forces in PEEK machining. In this paper, the milling simulations and experiments are carried out taking the milling forces as the study index. The results show that the absolute value of the relative error between the simulation results and the experimental ones are less than 5.6%, which testifies the effectiveness of the finite element model. Through the analysis of variance of the orthogonal experimental data, it can be concluded that both the axial depth of cut ap and the radial depth of cut ae have more significant influences on milling forces than the feed engagement fz. The significance order from large to small is the radial depth of cut ap, the axial depth of cut ae, and the feed engagement fz. This study can provide a practical reference for the milling process optimization of the PEEK material.

Due to its enhanced chemical and mechanical structure, Polyetheretherketone (PEEK) material has been widely employed as biomaterials for trauma, orthopedic, and spinal implants. But there is a lack of cutting forces in PEEK machining. In this paper, the milling simulations of single factor and orthogonal are carried out taking the milling forces as the study index. According to the results of single factor simulation, it is found that with the increasing of milling parameters ae, ap and fz, the milling force presents a trend of increasing, and the change is very obvious. However, with the increase of spindle speed, the milling force first increases, then decreases, and finally increases. The overall trend is small. Because the spindle speed has little influence on the milling force, so only select ae, ap, fz to conduct the orthogonal simulation. Through the analysis of variance of the orthogonal simulation data, it can be concluded that both the axial depth of cut ap and the radial depth of cut ae have more significant influences on milling forces than the feed engagement fz. The significance order from large to small is the radial depth of cut ap, the axial depth of cut ae, and the feed engagement fz. This study can provide a theoretical reference for the milling process optimization of the PEEK material.