Abstract
Current demands for flexible, individual microstructures in high quality result in high requirements for micro tools. As the tool size defines the minimum structure size, ultra-small tools are needed. To achieve tool diameters of 50 µm and lower, we investigate the complete manufacturing chain of micro machining. From the development of the machine tools and components needed to produce and apply the micro tools, the micro tools themselves, as well as the micro machining processes. Machine tools are developed with the possibility of producing the micro geometry (cutting edge design) of micro tools as well as plating processes to produce super abrasive micro grinding tools. Applying these setups, we are able to produce ultra-small micro grinding and micro milling tools with typical diameters of 50 µm and down to 4 µm. However, the application of such tools is very challenging. The article presents possibilities and limitations in manufacturing the micro tools themselves as well as microstructures made with these tools. A special emphasis will be on the influence of the tool substrate in micro milling and grain sizes in micro grinding.
Highlights
A component’s surface characteristics are crucial for its functionality, durability, and the quality at which it performs the task it is designed for
The precision 4-axes machine tool was used for the application of the micro pencil grinding tools (MPGTs), Figure 2
The investigations covered micro milling with micro end mills and micro grinding with micro pencil grinding tools
Summary
A component’s surface characteristics are crucial for its functionality, durability, and the quality at which it performs the task it is designed for. Heat treatment can increase a components hardness, change its metallurgical microstructure or reduce residual stresses [3]. Another way to influence the mechanical and physical properties of a component is manufacturing geometrically defined microstructures on its surface [4]. Due to the high accuracy, low achievable surface roughness, and very high geometrical flexibility of produced microstructures, machining processes like micro milling [12] and micro grinding are much more suitable for small batch production on the micron scale compared to mass production processes [13]. No references exist that evaluate the influence of the cemented carbide grain size on the performance of micro end mills. The influence of the size of the abrasive grits on the performance of MPGTs and the boundaries of electroless plating will be evaluated
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