Progressive wear based tool failure analysis during dry and MQL assisted sustainable micro-milling

• Chipping condition with the progressive wear of a coated micro-mill is established. • Wear proceeds sequentially through abrasion, delamination , adhesion, and chipping. • Face wear reaches up to 23 μm in dry cutting, and can be reduced by 37% with MQL . • Usage of higher feed per flute (2 – 3 times of fresh edge radius) is recommended. • MQL increases the ploughing-stresses making the tool-tip more prone to chipping. Micro-milling tools...