Micro/Meso-Scale Mechanical Machining 2020: A Two-Decade State-of-the-Field Review

Abstract

Micro/meso-scale mechanical machining (M4) processes are miniaturized versions of conventional machining processes such as milling, drilling, and turning, where material removal is accomplished by physical contact between the micro/meso-scale cutting tool and the workpiece. The objective of this review paper is to provide an assessment of the state-of-the-field related to M4 processes during the last two decades. Key systems-level issues related to the deployment of M4 processes including micro/meso-scale machine tool (mMT) design, sensing/calibration, cutting tools, and lubrication strategies are discussed. Emerging material systems are identified along with the specific challenges posed for the development of microstructure-based process models. The topic of micro/meso-scale machining dynamics is reviewed both in terms of recent research findings as well as unresolved challenges posed by the complexity of experimental characterization and modeling. Finally, key industry trends are discussed along with promising interdisciplinary drivers that are expected to influence this field in the upcoming decade.

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

“…Chip removal mechanisms are mostly influenced by the material type (metallic materials, polymers, ceramics, composites or sandwich structures) and its properties, followed by the tool geometry (rake angle, cutting edge radius, clearance angle, diameter etc. ), scale of machining (macro, micro, or nano) and the primary process parameters (cutting speed, feed rate, depth of cut) [56][57][58][59][60][61][62][63][64][65][66]. For example, the dominant chip removal mechanism for macro machining of a Ti6Al4V is shearing in the primary shearing zone [67], while the dominant chip removal mechanisms (CRMs) for macro machining of carbon fibre reinforced polymer (CFRP) composites are bending, delamination formation, crushing and shearing, depending mainly on the fibre cutting angle and tools' rake angle [68,69].…”

Process Chains for Micro-Manufacturing: Modeling and Case Studies

“…The subtractive, mass-containing, additive, and joining micro-manufacturing processes are still being widely investigated to improve the fabrication of micro-products in terms of productivity, accuracy, reliability, costs, and reproducibility. The latest developments are described in several recent review papers focused, for example, on chip removal (or mechanical) micro-machining [5][6][7][8], non-conventional subtractive processes [9][10][11][12], micro-forming [13][14][15][16], micro-AM [17,18]. Over the years, several different definitions of hybrid manufacturing processes have been provided [19][20][21].…”

“…Numerous conferences, precision engineering societies, national and international research networks, and journal special issues are focused on technologies, methodologies, process chains, and models for fabricating Micro-Featured High-Precision Components (MFHPCs). Despite this growing interest and the relevant paper production on this topic [2,[5][6][7][8][9][10][11][12][13][14][15][16][17][18]30], there need to be more contributions from a holistic point of view on the micro-manufacturing process chains and comprehensive models to address MFHPC manufacturing successfully.…”

Wettability and biological responses of titanium surface’s biomimetic hexagonal microstructure

“…23 The chemical methods that can be used to modify the surface of titanium metal include alkaline heat treatment, 24 acid etching, 25 anodizing, 26 and micro-arc oxidation. 27 The commonly used mechanical modification methods of titanium metal surface include micro milling, 28 turning, 29 laser processing, 30 etc. Among these methods, laser processing provides a fast and repeatable processing solution for implant materials.…”