Determination of minimum uncut chip thickness and size effects in micro-milling of P-20 die steel using surface quality and process signal parameters

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

“…This phenomenon causes more often difficulties in micro-milling than in conventionalsized machining. According to Vipindas et al [70], the cutting edge radius has the most significant influence on the size of the minimum chip thickness, as was confirmed by Wojciechowski et al [47], Dib et al [45], and Sahoo et al [20] as well. The minimum chip thickness can be quasiprecisely estimated by an empiric model developed by Gao et al [43] and Dib et al [45].…”

“…(ii) The uncut chip thickness is often in the same order of magnitude as the cutting edge radius or as the grain size of the workpiece material [2,32,42,43]. Therefore, the material deformation mechanisms are often dominated by the ploughing-effect [20,44], and the quality of the surface is often inadequate [42,45]. Furthermore, the value of the theoretical chip thickness is often similar to the size of the minimum chip thickness [20,45,46], which may prevent chip formation in each edge step-in [47,48].…”

“…Therefore, the material deformation mechanisms are often dominated by the ploughing-effect [20,44], and the quality of the surface is often inadequate [42,45]. Furthermore, the value of the theoretical chip thickness is often similar to the size of the minimum chip thickness [20,45,46], which may prevent chip formation in each edge step-in [47,48]. (iii) The ratio of the burr size to the size of the machined features is higher than it is used to in the case of the conventional machining operations, the cost and time needs of the micro-deburring processes have therefore more effect on the final cost of the products [49,50].…”

“…In the captured images, the tool can be in any positions, and the algorithm can evaluate it correctly. This is based on the fact that the size of the tool (which perpendicular to the cutting edges of the tool) does [4], [33], [38], [46], [48], [51], [54], [83], [88], [89], [122], [133], [144], [164], [165], [166], [167], [168] AISI 1015: [169] AISI 1018: [125] AISI 1040: [77] AISI 1050: [37] AISI 4340: [119], [139], [170] AISI P20: [20], [145], [164] S960QL: [171] NAK80: [123], [172], [173], [174] AISI A2-annealed: [175] 42CrMo4: [167] X13NiMnCuAl4-2-1-1: [146] SK2: [176] Hardened steels AISI H13: [2], [30], [42], [72], [80], [164], [177], [178], [179],…”

“…Miniaturised components can be manufactured by (i) electro-discharge machining [7][8][9][10], (ii) laser micromanufacturing [11][12][13], (iii) lithography, electroplating and moulding (LIGA) [14,15], (iv) deep reactive ion etching [16,17], (v) deep UV lithography [18,19] or (vi) mechanical micromachining [20][21][22][23][24] technologies. Excellently precise geometrical features and small tolerances can be achieved by these micromachining technologies; however, their operation time and cost are often extremely high.…”