In this paper, we give a detailed mathematical understanding of flank milling with flat end cutters, which we use to develop a method for milling with such a cutter. This method slides the cutter along two rails, providing two points of contact on the surface.

This work presents a PCD (polycrystalline diamond) end mill with a new staggered structure for the milling of CFRP (carbon fiber reinforced plastic). The magnitude and direction of cutting force is decreased and changed by side-edge re-configuration of the structure. The flute and insert pocket of the staggered PCD end mill are designed considering the tool’s stiffness and welding process. The ...

The effect of run-out is clearly noticed in micro-end-milling operations, while the same run-out creates negligible change at the cutting force profile of conventional end-milling operations. In this paper, the cutting force characteristics of micro-end-milling operations with tool run-out are investigated. An analytical cutting force model is developed for micro-end-milling operations with too...

Two types of end milling at partial radial immersion are distinguished in this work, namely; up and down end-milling. They are theoretically given comparative study for a three tooth end miller operating at 0.5, 0.75 and 0.8 radial immersions. 0.5 and 0.8 radial immersion conditions are chosen so that analysis covers situations in which repeat and continuous tool engagements occur while 0.75 ra...

This paper discusses the fabrication of microfluidic channels using micro end milling and micro electrical discharge (ED) milling on metals and polymers. The width of the microchannels fabricated by micro end milling was 100-800 μm with 1-2 aspect ratio. The average surface roughness values were 100-200 nm and 80-120 nm on metals and polymers respectively. The end milling was found to form more...

In any machining operations, quality and productivity are the two important conflicting objectives. In order to give assurance for high productivity, some extent of quality has to be compromised. Similarly productivity will be decreased while the efforts are channelized to enhance quality. Therefore it is essential to optimize both quality and productivity simultaneously. Surface roughness and ...

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For time and cost saving reasons, the lowest surface roughness possible is sought in milling operations. High speed milling is recommended in order to minimise the amount of material to be removed in subsequent finishing operations, e.g. grinding, electrical discharge machining or manual polishing. Several roughness parameters are usually employed for the characterization of polished surfaces. ...

For microfabrications of biochips with micro fluidic channels, a large number of microfabrication techniques based on silicon or glass-based Micro-Electro-Mechanical System (MEMS) technologies were proposed in the last decade. In recent years, for low cost and mass production, polymer-based microfabrication techniques by microinjection molding and micro hot embossing have been proposed. These t...