High-Speed Micro-Machining of T2 Copper: Modelling and Validation

This study systematically investigates the size effect mechanism and its influence on machining quality during micro-milling of T2 copper through an integrated approach combining numerical simulation and experimental validation.A 3D dynamic finite element model with realistic tool geometry was developed in ABAQUS/Explicit, employing the Johnson-Cook constitutive model for thermomechanical behaviour.The results reveal a fundamental transition in material removal mechanism at a critical feed per tooth of 0.22 μm/z, where the dominant process shifts from ploughing-dominated to shear deformation-dominated regime.Experimental validation using a JTGK-600 micro-milling system equipped with piezoelectric dynamometry confirmed the simulation accuracy with errors below 10 % (p < 0.05).At the optimal feed rate of 0.44 μm/z, cutting forces decreased by 28 % and surface quality improved by 42 %, with SEM and 3D topography confirming suppressed ploughing effects.These findings provide optimized process parameters for copper-based MEMS fabrication and demonstrate the efficacy of ABAQUS in micro-cutting simulations.