Micro milling process modeling: a review

Abstract

The trend towards miniature manufacturing in high technological fields like bioengineering, electronics and aerospace has increased dramatically over the last decade. Many methods of micro manufacturing have been researched and applied to manufacture small scale components. Among these manufacturing methods micro-mechanical machining methods have shown themselves to be attractive alternatives. Micro milling is one of the most frequently used micro-mechanical machining method with high potential for the precise manufacturing of complex parts. The aim of this work is to present the principal aspects related to micro milling technology, with emphasis on process modeling and quality of the finished product. A general view on process modeling starting from chip thickness models up to tool and workpiece machining induced distortion models is depicted. Specifically, different modeling techniques related to modeling of micro milling process are evaluated and important aspects that authors revealed during their research are presented. Finally, implications are discussed and suggestions for future research are presented.

Micromachining and Its Applications for Electronics

“…Simulation and modeling: Advancements in simulation software have enabled accurate prediction of tool behavior, cutting forces, and surface quality during micromilling. These models aid in optimizing tool paths, reducing vibration, and improving dimensional accuracy [55,56].…”

Meso scale component manufacturing: a comparative analysis of non-lithography and lithography-based processes

“…Very large spindle speed is required to maintain the cutting speed, due to small tool diameter. Tool deflection in smaller tools is a significant problem [29]. In micro turning, workpiece loses rigidity and deflect due to thin cross-section.…”

Chatter detection in milling processes—a review on signal processing and condition classification

“…Due to the high number of studies on chatter and the relevant areas, there have been diverse reviews published with related topics to the study of chatter detection, as follows. Chatter in milling literature has been reviewed in three different articles by Quintana [1,9,11], while Wu et al reviewed chatter in thin-wall machining [12]; robotic machining studies have been discussed by Pan et al and Yuan et al [13,14], and Yan et al focused on blade milling [15], along with other reviews on the mathematical models of chatter and machining dynamics by Altintas et al [3,16], Mamedov et al [17] and Insperger et al [18], and the review on vibration measurement by Murthy et al [19]. Besides, Teti et al [20] reported strategies for process monitoring, while Jardine et al [21] reviewed the diagnostics of mechanical systems.…”