In the current context of miniaturization, micro-machining processes are in full expansion. One of them is micro-milling. Although micro-milling is based on the same principle as macro-milling, the phenomena of micro-cutting are not a simple scaling of macrocutting. A significant difference is the chip formation involving the phenomenon of minimum chip thickness. In micro-milling the depth of c...

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...

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...

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...

the micro milling operation is one of the manufacturing processes, which can produce 3d parts in the range of less than a millimetre. miniaturization of components results in increasing the ratio of surface area to volume of components, which in turn increases the role of surface on the component performance. therefore, anticipating the relationship between micro milling parameters and surface ...

This paper presents the prediction of micro-milling forces using the finite element method (FE). An FE model of orthogonal micro-cutting with round cutting edge is developed. The cutting force coefficients are identified from a series of FE simulations at a range of cutting edge radii and chip loads. The identified cutting force coefficients are used to simulate micro-milling forces. The simula...

Laser milling provides a new method of producing components for the micro tool manufacturing industry. This paper considers the technical capabilities of laser milling when applied to the machining of components for micro tooling. Characteristics important for laser milling as a micro tooling manufacturing process are reviewed. These characteristics are surface finish, aspect ratio, dimensional...

Tool wear, minimum chip thickness and micro tool geometry are found to have a significant influence on the surface roughness through experimental analysis of the micro-end-milling process. To address these issues, a surface roughness model is developed and validated in this present work. Firstly, experimental analysis for the tool wear and surface roughness was performed based on the micro-end-...

Micro end-milling method is a universal micro manufacturing method, which can be used to fabricating complex 3D structures and parts with many materials. But compared with their micrometer order size, their surface roughness quality is not satisfied. In this paper, the different metal phase grains influences are researched, and the micro end-milling process is described while the material is an...

In order to machine micro structured dies and molds made of ceramics, micro milling tools made of poly-crystalline diamond (PCD) are developed. Many cutting edges are ground with diamond wheels. Tool wears of the PCD milling tool are evaluated by cutting spherical molds made of binder-less tungsten carbide and structured surfaces are machined for trial. From the experiments, it is clarified tha...