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.
Highlights
Micro milling is widely used in high-tech industries such as biomedical, aerospace, optics, electronics and die-mold with the increasing demand for precisely manufactured miniature parts
Previous research showed that micro milling is not exactly the scaled down version of conventional milling
It is important to emphasize that in the last decade the demand for the parts produced with micro machining process has drastically increased
Summary
Micro milling is widely used in high-tech industries such as biomedical, aerospace, optics, electronics and die-mold with the increasing demand for precisely manufactured miniature parts. These industries have a high demand for tight manufacturing tolerances and surface quality. They have complex geometries, which require micron level accuracy. The demand for smaller and durable components with high number of functions has imposed strong requirements on manufacturing processes. Ultra-precise manufacturing requires understanding of the fundamentals of micro cutting process such as chip formation, kinematics, dynamics, thermal aspects and surface integrity. Researchers work on the causes and correlates of these fundamentals in order to understand how they differ from macro scale machining
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