A review on micro-milling: recent advances and future trends

Balázs, Barnabás Zoltán; Geier, Norbert; Takács, Márton; Davim, J. Paulo

doi:10.1007/s00170-020-06445-w

Cited by 124 publications

(52 citation statements)

References 290 publications

(544 reference statements)

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“…With an increase in the radius of the cutting edge about the thickness of the cut layer, the deformation area of the workpiece increases, and as a result, the force load on the tool tooth increases [31]. Cutting forces have a great influence on the chip formation nature, the process of material cutting, vibration characteristics of cutting, the integrity of the cutting tool, and the surface quality [59][60][61][62]. Additional surface treatment by fast atoms will reduce the cutting edge radius and prepare surfaces for the deposition of a wear-resistant coating while providing a relatively smaller radius of the cutting edge than when coating the surface without preparation of this kind.…”

Section: Discussionmentioning

confidence: 99%

Combined Processing of Micro Cutters Using a Beam of Fast Argon Atoms in Plasma

et al. 2021

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We present a new method for coating deposition on micro cutters without an increase in their cutting edges radii caused by the deposition. For this purpose, the cutting edges are sharpened before the coating deposition with a concentrated beam of fast argon atoms. The sharpening decreases the initial radius and, hence, limits its value after the coating deposition. The concentrated beam of fast argon atoms is generated using an immersed in the gas discharge plasma concave grid under a negative high voltage. Ions accelerated from the plasma by the grid pass through the grid holes and are concentrated in the focal point of the grid. As a result of the charge exchange in the space charge sheaths of the grid, they are transformed into fast atoms. A uniform sputtering by the fast atoms of the micro-cutter surface reduces the radius of its cutting edge.

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Section: Discussionmentioning

confidence: 99%

Combined Processing of Micro Cutters Using a Beam of Fast Argon Atoms in Plasma

et al. 2021

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“…[39], Balázs et al [40], Masuzawa [41], De Oliveira et al [42]). The following sections cover micro-machining of AM metals and conventional metals due to limited published literature on micro-machining of AM metals.…”

Section: Machining Of Additively Manufactured Metalsmentioning

confidence: 99%

Micro-machining of additively manufactured metals: a review

Gomes

Santos

Oliveira

et al. 2021

Int J Adv Manuf Technol

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Metal additive manufacturing (MAM) has attracted significant interest in both academia and industry to produce near-netshape engineering components. The inherent defects in MAM, however, require suitable subtractive techniques as postprocesses to control dimensional and geometric tolerances as well as surface finish. The additively manufactured metals, with different microstructures than the wrought materials that produced by conventional routes, need different approaches and parameters when being machined. This review covers recent published literature on traditional micro-machining as a post-processing operation for MAM and recommends future directions. The text presents a brief review on the main AM processes followed by a comprehensive conventional micro-milling and microdrilling, as well as applications for micromachining. Micro-tool assessment, built-up-edge prediction and prevention, and link of macro/micro-machining are areas for future research.

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“…30 Moreover, based on scientific literature, relatively few publications deal with the micro-milling of these difficult-to-cut materials. 31,32 Therefore, and due to the excellent properties such as excellent hot tensile properties, high hot wear resistance, adequate toughness and heat checking resistance, hardened AISI H13 was chosen for our investigation. Moreover, the corrosion resistance of the injection moulding tools can be also a critical property, therefore Böhler M303 was chosen as second workpiece material for the experiments.…”

Section: Introductionmentioning

confidence: 99%

“…face milling, 33,34 hard turning, 35 etc.). Efficient machining of hardened steel is a great challenge; 36 moreover, recently, the role of sustainable and eco-friendly machining is highly growing, 31,37 therefore optimising the process could be of utmost importance in many cases. 33–35,38 Abbas et al.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

Balázs

Takács

2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

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A review on micro-milling: recent advances and future trends

Cited by 124 publications

References 290 publications

Combined Processing of Micro Cutters Using a Beam of Fast Argon Atoms in Plasma

Combined Processing of Micro Cutters Using a Beam of Fast Argon Atoms in Plasma

Micro-machining of additively manufactured metals: a review

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

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