Burr formation and surface roughness characteristics in micro-milling of microchannels
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ORIGINAL ARTICLE
Burr formation and surface roughness characteristics in micro-milling of microchannels Liang Chen 1 & Daxiang Deng 2 & Guang Pi 1 & Xiang Huang 3 & Wei Zhou 1 Received: 22 March 2020 / Accepted: 24 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Microchannels are attractive for their widespread applications in electronics, biological, chemical, and energy areas. Micromilling provides an ideal method to fabricate microchannels, whereas problematic burr formations and inherent rough surfaces of microchannel bottom and sidewalls are still far from sufficiently known. In this study, micro-milling process of rectangular copper microchannels was conducted by a two-flute tungsten carbide micro-end mill. Burr formation mechanism was studied via 3D finite element simulation together with experiment observations. Surface quality of microchannels, i.e., burr size and surface roughness, was studied in different spindle speeds, feed rates, and depths of cut. It was found that the top burr sizes on the downmilling side of microchannels were much larger than those on the up-milling side. The top burr size on the down-milling side and surface roughness on bottom and both sidewalls of microchannels presented a monotonic decreasing trend when the spindle speed increased, and an increasing trend with increasing depth of cut. Nevertheless, they firstly decreased due to the plowing and extruding effect together with elastic recovery when the feed rate was smaller than the tool cutting edge radius, and then changed to increase due to the shearing and cutting process after the feed rate exceed the tool cutting edge radius. High spindle speed, small depth of cut, and moderate feed rate close to the tool cutting edge radius seem to be favorable to improve surface quality of micro-milled microchannels. Keywords Microchannels . Micro-milling . Burr . Surface roughness
1 Introduction Microchannels have been widely recognized to be an ideal integral component for their widespread applications in microchannel heat exchanger, micro-biochips, micro-reactors, and micro-fuel cells in electronics, biological, chemical, and energy areas [1, 2] since 1981 by Tuckerman and Pease [3]. By controlling, delivering, manipulating, and storing fluid within a miniature area, microchannels feature many promising advantages, such as large heat transfer surface area,
* Daxiang Deng [email protected] 1
Department of Mechanical & Electrical Engineering, Xiamen University, Xiamen 361005, China
2
School of Mechanical Engineering and Automation, Harbin Institute of Technology, Shenzhen, Shenzhen 518055, China
3
School of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, China
excellent heat transfer capacities, compact dimensions, and effectiveness in flow distribution and controlled pressure drop. Therefore, lots of research efforts have been devoted to developing microchannels employing different fabrication methods, such as etching [4], photolithography [5], wire electrica
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