Abstract
Due to the constant need for better functionalized surfaces or smaller, function integrated components, precise and efficient manufacturing processes have to be established. Micro milling with micro end mills is one of the most promising processes for this task as it combines a high geometric flexibility in a wide range of machinable materials with low set-up costs. A downside of this process is the wear of the micro end mills. Due to size effects and the relatively low cutting speed, the cutting edge is especially subjected to massive abrasive wear. One possibility to minimize this wear is coating of micro end mills. This research paper describes the performance of eight different hard coatings for micro end mills with a diameter <40 µm and discusses some properties for the best performing coating type. With this research, it is therefore possible to boost the possibilities of micro milling for the manufacture of next generation products.
Highlights
Individualized and miniaturized products are getting more common, especially for medical devices or electronic consumer products
One of the most promising processes for this task is micro milling with micro end mills
It combines a high geometrical flexibility with the possibility to machine almost any workpiece material. When it comes to prototypes or the manufacture of small batch numbers, it is more economic compared to other micro production processes due to its low set-up costs [2]
Summary
Individualized and miniaturized products are getting more common, especially for medical devices or electronic consumer products. One of the most promising processes for this task is micro milling with micro end mills It combines a high geometrical flexibility with the possibility to machine almost any workpiece material. These coatings enhance tool life through a higher hardness, a higher resistance against abrasive wear, and a higher chemical stability [4] Those coatings are not deeply researched when it comes to micro milling with micro end mills (diameter < 100 μm). The coating increased the radius of the cutting edges which in turn leads to higher friction, lower cutting capabilities and higher wear This is the reason why the coating has to be extremely thin or the micro end mill optimized for roughing operations with a high feed per tooth [5]
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