Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

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Precision micro-milling process: state of the art

In the high speed milling, the tool run-out affects the cutting force greatly and results in pre-matured tool life. To investigate this relationship, an improved instantaneous milling force per tooth is proposed, with inclusion of tool run-out effect. The un-deformed chip thickness considering tool run-out are defined and modeled, according to the geometrical relationships and axial milling ranges per tooth. Meanwhile, instead of the studying the conventional average flank wear, tool wear per tooth is studied for more sensitive correlation with force. Based on milling tests with Inconel 718, the error of the force model prediction is found less than 1% against the experimental data, and the correlation between the axial instantaneous milling force and tool wear per tooth is above 0.9. The results have shown that the proposed model can accurately describe the instantaneous force per tooth including tool run out effect, and the axial force component is a good indication of tool wear condition.

Modeling of the instantaneous milling force per tooth with tool run-out effect in high speed ball-end milling

At mesoscale, the blade of micro impeller with Ti-6Al-4V titanium alloy (micro thin wall with mixed boundaries) is a thin-walled structure, characterized by small size, low stiffness, high surface precision, complex boundaries, and difficult-to-control machining deformation. To control and reduce the deformation of micro thin wall, it is necessary to study the micro-deformation mechanisms during milling micro thin-wall parts. In side milling of micro thin wall with mixed boundaries, the micro thin wall suffers from dynamic alternating forces, and the deformation modes are complex, so the direct and accurate theoretical modelling is difficult to make. Since the feed speed in milling micro thin wall is less, the small deformation of micro thin wall can be described based on the flexure deformation model of the thin plate subjected to elastic loadings. Firstly, accompanied by the reciprocal theorem of work for a curved thin plate, Kirchhoff-Love small deformation model of micro thin wall is used to establish the deformation equation and boundary conditions of micro thin wall with mixed boundaries under concentrated milling forces. Thus, the obtained boundary conditions are mainly applied to the subsequent finite element simulation of three-dimensional milling deformation of micro thin wall. Then a three-dimensional deformation simulation of the micro thin wall under different milling parameters is carried out by considering the micro-walled structure, material elasto-plastic constitutive model, the stiffness and geometric structure of micro milling tools in finite element method. In the workpiece constitutive modelling, considering the strain gradient plastic model in micro milling of Ti-6Al-4V titanium alloy, the workpiece plastic constitutive model is modified by introducing the intrinsic characteristic length of the material to describe the size effects in mesoscale micro milling. Finally, a series of the corresponding experiments on the milling of titanium alloy micro thin walls are carried out. By comparing and analyzing the experimental values and finite element numerical results of the micro thin-walled deformation, the micro deformation mechanisms in milling of thin wall are revealed. It also verifies the accuracy and effectiveness of this established milling finite element model of thin wall, and provides theoretical basis and technical support for controlling the milling deformation of micro thin-walled parts.

Research on deformation law and mechanism for milling micro thin wall with mixed boundaries of titanium alloy in mesoscale

Generic instantaneous force modeling and comprehensive real engagement identification in micro-milling

Vibration-assisted cutting is an important technology with better performance in manufacturing micro-scaled components, compared with conventional cutting technology. This article first illustrates...

Development of vibration-assisted micro-milling device and effect of vibration parameters on surface quality and exit-burr:

Geometry defect of tools and assembling error (such as tool runout) is inevitable in the machining process and cannot be ignored in micro-milling processing mechanism. Besides, it also impacts the micro-milling force. Therefore, it plays an important role on impacting surface quality in micro-milling. In the present paper, the milling force model is established for the micro-milling process with considering tool runout, undeformed chip thickness, tool slope angle, shear angle, friction angle, and equivalent rake angle. The model for three-directional micro-milling force is proposed. Furthermore, the cutting forces with different tool runouts are analyzed. The formation of the step that is on the surface and found in the experiments is made clear. Titanium alloy is applied in a series of micro-milling experiments to verify the model of micro-milling force with analyzing the step widths of machined groove edges. The micro-milling process is further comprehended though the model. It helps to judge the surface quality that is affected by tool runout though the analysis of variation of milling force.

Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout

The invention discloses a two-dimensional vibration device based on different placing directions of piezoelectric ceramic shorn pieces, belongs to the technical field of energy auxiliary machining, and aims to solve the problems of incapability of adjusting the vibration frequency of a resonant vibration device and non-uniform and untidy knife patterns of machining workpieces in the machining of thin-wall microcomponents in a traditional high-precision inertial navigation sensor and the problems of weak piezoelectric property and unconspicuous vibration under the condition of long ceramic working time in a traditional non-resonant vibration device. A first set of piezoelectric ceramic shorn pieces is clamped between a first electric conducting electrode piece and a second electric conducting electrode piece; a second set of piezoelectric ceramic shorn pieces is clamped between the second electric conducting electrode piece and a third electric conducting electrode piece; a third set of piezoelectric ceramic shorn pieces is clamped between the third electric conducting electrode piece and a fourth electric conducting electrode piece; and a fourth set of piezoelectric ceramic shorn pieces is clamped between the fourth electric conducting electrode piece and a fifth electric conducting electrode piece. The device realizes two-dimensional vibration by using different placing directions and different electric field application directions of the piezoelectric ceramic shorn pieces.

Two-dimensional vibration device based on different placing directions of piezoelectric ceramic shorn pieces

A one-dimensional vibration device based on the inverse piezoelectric effect of a piezoelectric ceramic piece belongs to the technical field of energy assistedmachining, and aims at solving the problems that when a thin-wall micro component in the existing high-precision inertial navigation sensor is processed, the used one-dimensional vibration device has a nonadjustable frequency in resonant mode vibration, tool lines are littery and uneven in depths, and the residual stress is large. A first bolt of the one-dimensional vibration device penetrates through a through hole in a workbench left side plate, a left side first piezoelectric ceramic ring group, a through hole of a vibration platform, a right side first piezoelectric ceramic ring group and a first spherical washer to be in threaded fastening connection with a threaded hole of a workbench right side plate; and a second bolt penetrates through a through hole of the workbench left side plate, a left side second piezoelectric ceramic ring group, a through hole of the vibration platform, a right side second piezoelectric ceramic ring group and a second spherical washer to be in threaded fastening connection with a threaded hole of the workbench right side plate. According to the invention, the inverse piezoelectric effect of piezoelectric ceramic is utilized, the vibration platform is pushed to move towards one direction, and the vibration frequency is adjustable.

One-dimensional vibration device based on inverse piezoelectric effect of piezoelectric ceramic piece

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Modeling and experimental study on the force of micro-milling titanium alloy based on tool runout

Two-dimensional vibration device based on different placing directions of piezoelectric ceramic shorn pieces

One-dimensional vibration device based on inverse piezoelectric effect of piezoelectric ceramic piece