The market for freeform and high quality microdies and moulds made of steel is predicted to experience a phenomenal growth in line with the demand for microsystems. However, micromachining of hardened steel is a challenge due to unpredictable tool life and likely differences in process mechanism compared to macro-scale machining. This paper presents an investigation of the size effect in micromilling of H13 hardened tool steel. In this case, the size effect in micromilling hardened tool steel was observed by studying the effect of the ratio of undeformed chip thickness to the cutting edge radius on process performance. The paper explores how this ratio drives the specific cutting force, surface finish and burr formation in micro-scale machining. In addition, the effect of different microend mill geometry on product quality was explored. The paper provides a valuable insight into optimum micro-scale machining conditions for obtaining the best surface finish and minimizing burr size.

Size effect and tool geometry in micromilling of tool steel

An experimental investigation of the effect of coating material on tool wear in micro milling of Inconel 718 super alloy

Micro milling cutters or micro mills are unique and important micro tools for fabricating miniaturised devices with sufficient geometrical and dimensional accuracy and machined surface integrity. Micro milling cutters, compared to conventional macro tools, have significantly different material removal mechanisms. They are also made of different raw materials and structures and exhibit distinctive machining characteristics and performances. Herein, we present the first comprehensive and up-to-date review of micro milling cutters in terms of their uniqueness, material removal mechanisms, materials and compositions, structures and design, fabrication techniques and machining performances, to provide adequate guidance for interested involvers. We also outline and discuss several possible future research directions to offer potential insights for the micro milling community and future researchers.

Advances in micro milling: From tool fabrication to process outcomes

Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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A review on micro-milling: recent advances and future trends

Micromilling of metallic materials

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Micromilling of metallic materials