Fabrication of Micro-end Milling Cutter Based on WEDG

Abstract

The effect of unbalance caused by installation error is the one of the main reasons for tool runout in micro milling processes, especially at high-speed on the spindle. As tool runout contributes significant impact to the machining accuracy in micro milling processes, an on-machine fabrication method which could avoid the existence of installation error of spindle deviation and tool tilt caused by off-line of micro-end milling cutter has been proposed. To verify the possibility of an on-machine fabrication method based on wire electro-discharge grinding, a micro-EDM machine with an ultra-high-speed air turbine spindle and a geometrically optimized tool design were developed. Ultra-fine grain carbide end mills with the target diameter equal to 50 μm were fabricated by wire electro-discharge grinding based on the on-machine fabrication method. And some micro slot milling experiments were conducted in pure copper. The experimental results indicate that the micro cutting process using the on-machine fabricated tool by wire electro-discharge grinding is possible. Moreover, this method can improve the reliability of the cutter and the processing accuracy of the parts, avoids the error caused by the second clamping of the micro-milling cutter and improves the overall quality of micro-milling.