Abstract
Recently micromilling has been increasing in not only mechanical industry but also chemical and bio-medical industries. Then, drastic progress has been seen in the micromilling with the technology in micro/nano-scale measurement, control and micro tooling. This chapter describes the typical processes in micromilling with the technical issues for micro manufacturing. In the introduction, the aim of this chapter is shown with the applications of the micromilling. Then, the second section describes the micromilling tools and some issues in manufacturing the end mills. In the third section, the micromilling process is discussed from the point of the machining operations. Cutter runout and tool deflection in micromilling are discussed to realize stable milling operations. In the fourth section, chip formation and a cutting force model are described to understand the micro cutting. Then, the intermittent chip formation in micromilling is described with introducing a model. The fifth section discusses the micromilling in terms of materials. The size and the orientation of crystal grains should be discussed in micromilling. The micro cuttings of fine-grained materials are compared with those of the standard grain-sized materials. Then, the micromilling of fine-grained stainless steel is discussed in terms of the cutting force, the surface finish, and the affected layer. Burr formation is relatively large compared to the micro parts in micromilling. A deburring approach is introduced for improvement of the machining quality. Then, micromilling of brittle materials is described with the applications. The effect of the cutter axis inclination on the cutting process is discussed with a cutting model and a surface finishing model. The last section concludes the issues of the micromilling for the future machining.
Published Version
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