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A new tool force model to be presented is based upon process geometry and the characteristics of the force system,in which the forces acting on the tool rake face,the cutting edge rounding and the clearance face have been considered,and the size effect is accountable for the new model.It is desired that the model can be well applicable to conventional diamond ting and the model may be employed as a tool in the design of diamond tools.This approach is quite different from traditional investigations primarily based on empirical studies.As the depth of cut becomes the same order as the rounded cutting edge radius,sliding along the clearance face due to elastic recovery of workpiece material and plowing due to the rounded cutting edge may become important in micro-machining,the forces acting on the cutting edge rounding and the clearance face can not be neglected.For this reason,it is very important to understand the influence of some parameters on tool forces and develop a model of the relationship between them.