Modeling and Simulation of Mechanical Micro-Machining—A Review

This article provides a comprehensive review of literature on modeling and simulation that enhances the understanding of the process physics of the rapidly growing field of mechanical micro-machining. The article focuses on a number of micro-scale machining issues such as size effect, minimum chip thickness effect, micro-structure effects, and cutting tool dynamics which influence the underlying cutting mechanisms and the generated surface finish. We review the recent advances in modeling and simulation techniques, which include molecular dynamics simulation, finite element method, the newly emerging field of multi-scale simulation and mechanistic modeling. Some comments to emphasize the future requirements and directions of the modeling and simulation efforts in this field are also offered.