Precision micro-milling process: state of the art
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Precision micro-milling process: state of the art Lorcan O’Toole1 • Cheng-Wei Kang1 • Feng-Zhou Fang1,2
Received: 8 March 2020 / Revised: 11 June 2020 / Accepted: 30 August 2020 Ó The Author(s) 2020
Abstract 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 micropatterning, 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
& Feng-Zhou Fang [email protected] 1
Center of Micro/Nano Manufacturing Technology (MNMTDublin), University College Dublin, Dublin 4, Ireland
2
State Key Laboratory of Precision Measuring Technology and Instruments, Center of Micro/Nano Manufacturing Technology (MNMT), Tianjin University, Tianjin 300072, People’s Republic of China
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. Keywords Precision machining Micro-milling Size effect Deflection Runout Tool wear
1 Introduction The trend toward miniaturization of precision micro-components, such as for microelectromechanical, nanoelectromechanical, and micro-medical systems, has led to advances in microfabrication techniques in recent years. This demand for micro-sized parts with high aspect ratios has necessitated the biomedical, electronics, automotive, and aerospace industries to adopt and apply both new and old manufacturing processes at the microscale. Although microfabrication techniques have existed for many years, the stringent requirements of extremely tight tolerances on form, dimension, and surface characteristics [1], high machining efficiency, and mac
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