Micromilling research: current trends and future prospects

Serje, David; Pacheco, Jovanny; Diez, Eduardo

doi:10.1007/s00170-020-06205-w

Cited by 14 publications

(4 citation statements)

References 144 publications

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“…While there has been rising interest in micromilling research over the past decade, the majority of studies involving metallics have focused on materials such as steels, copper and aluminium alloys [ 7 ]. In contrast, the published literature relating to the machining of single-crystal nickel-based superalloys using small-diameter cutting tools remains limited [ 8 ]. According to Câmara et al [ 9 ], micromilling can be defined based on the diameter of the cutting tool when in the region of 1–1000 µm, but they emphasise that a more important distinguishing factor is that the undeformed/uncut chip thickness (h) tends to be in the order of the tool cutting-edge radius (r e ) and grain size of the workpiece material.…”

Section: Introductionmentioning

confidence: 99%

Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy

et al. 2023

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This paper details an experimental investigation on the influence of the size effect when slot-milling a CMSX-4 single-crystal nickel-based superalloy using 1 mm- and 4 mm-diameter TiAlN-coated tungsten carbide (WC) end-mills. With all tools having similar cutting-edge radii (re) of ~6 µm, the feed rate was varied between 25–250 mm/min while the cutting speed and axial depth of cut were kept constant at 126 m/min and 100 µm, respectively. Tests involving the Ø 4 mm end-mills exhibited a considerable elevation in specific cutting forces exceeding 500 GPa, as well as irregular chip morphology and a significant increase in burr size, when operating at the lowest feed rate of 25 mm/min. Correspondingly for the Ø 1 mm micro-end-mills, high levels of specific cutting forces up to ⁓1000 GPa together with severe material ploughing and grooving at the base of the machined slots were observed. This suggests the prevalence of the size effect in the chip formation mechanism as feed per tooth/uncut chip thickness decreases. The minimum uncut chip thickness (hmin) when micromilling was subsequently estimated to be less than 0.10 re, while this increased to between 0.10–0.42 re when machining with the larger Ø 4 mm tools.

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Section: Introductionmentioning

confidence: 99%

Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy

et al. 2023

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“…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].…”

Section: Introductionmentioning

confidence: 99%

“…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.…”

Section: Introductionmentioning

confidence: 99%

Process Chains for Micro-Manufacturing: Modeling and Case Studies

Basile,

Modica,

Rebaioli

et al. 2023

JMMP

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As the complexity of micro-products increases, the micro-manufacturing processes, tool setups, and measurement processes have to be more precise and efficient. Combining them in a multi-stage process chain can effectively improve production accuracy and performance and reduce limitations and production costs. This paper focuses on the process chains for the manufacturing of micro-products and presents the state of the art, highlighting the specific characteristics of the existing models of process chains for micro-manufacturing. Based on the critical review of these characteristics, an evolution of the process chain model for micro-manufacturing is proposed, considering machining, measurement/characterization, referencing processes, and their combination into a suitable sequence. The proposed model accounts for relevant aspects of micro-manufacturing, such as size effects and technological fingerprints at the microscale. This paper also discusses the hierarchical properties of multiple micro-manufacturing process chains and some specific techniques to address the critical issue of referencing processes. Furthermore, some relevant case studies involving micro-electrical discharge machining, micro-injection molding, additive manufacturing, and micro-milling are presented to demonstrate how the micro-manufacturing potentiality can be increased using process chains.

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“…A more detailed measure of peaks and valleys sharpness is provided by S ku where, a smooth surface is individuated by a value lower than 3, while above this value the surface shows sharp asperities. The high precision along the surfaces requested to guarantee accurate contact between the component faces in horology, makes the evaluation of roughness parameters an attractive technique for quality assessment in watchmaking industry [35]. The sampling area A employed in these measurements was selected on the base of the pocket and it was equal to 1 mm × 1 mm.…”

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confidence: 99%

Experimental Optimization of Process Parameters in CuNi18Zn20 Micromachining

et al. 2021

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Ultraprecision micromachining is a technology suitable to fabricate miniaturized and complicated 3-dimensional microstructures and micromechanisms. High geometrical precision and elevated surface finishing are both key requirements in several manufacturing sectors. Electronics, biomedicals, optics and watchmaking industries are some of the fields where micromachining finds applications. In the last years, the integration between product functions, the miniaturization of the features and the increasing of geometrical complexity are trends which are shared by all the cited industrial sectors. These tendencies implicate higher requirements and stricter geometrical and dimensional tolerances in machining. From this perspective, the optimization of the micromachining process parameters assumes a crucial role in order to increase the efficiency and effectiveness of the process. An interesting example is offered by the high-end horology field. The optimization of micro machining is indispensable to achieve excellent surface finishing combined with high precision. The cost-saving objective can be pursued by limiting manual post-finishing and by complying the very strict quality standards directly in micromachining. A micro-machining optimization technique is presented in this a paper. The procedure was applied to manufacturing of main-plates and bridges of a wristwatch movement. Cutting speed, feed rate and depth of cut were varied in an experimental factorial plan in order to investigate their correlation with some fundamental properties of the machined features. The dimensions, the geometry and the surface finishing of holes, pins and pockets were evaluated as results of the micromachining optimization. The identified correlations allow to manufacture a wristwatch movement in conformity with the required technical characteristics and by considering the cost and time constraints.

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Micromilling research: current trends and future prospects

Cited by 14 publications

References 144 publications

Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy

Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy

Process Chains for Micro-Manufacturing: Modeling and Case Studies

Experimental Optimization of Process Parameters in CuNi18Zn20 Micromachining

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