Study on the burr formation process in micro-milling of high aspect ratio structures

SKD11 is widely used in manufacturing die. With the development of industrial level, size die further reduced, and difficult processing problem high aspect ratio (HAR) micro-structures exposed. Micro-milling a suitable method for machining HAR micro-structures; however, inevitable generation burrs deteriorates machined surface. Previous studies have mostly focused on burr formation process shallow grooves but ignored grooves. This paper investigated mechanism (2:1) harden steel (SKD11). Due to fact that was be observed actual micro-milling process, finite element model established. A corresponding experimental research conducted, which revealed good consistency between simulation results. Moreover, new type formed sidewall groove, transformed from top named as side burr. The results demonstrated chip flow rake face micro-mill hindered by sidewall, caused crumbling, accumulation, surface scraping, seriously affecting mechanism. SKD11, provides basic data with complex structure small size.