Article
Engineering, Manufacturing
Jinjin Han, Rui Ma, Linglei Kong, Xiuqing Hao, Ni Chen, Liang Li, Ning He
Summary: In this study, the chip formation mechanism of micro-structures with High-Aspect Ratio was thoroughly investigated, considering the minimum cutting thickness, tool types, and milling parameters. The results show that the performance of the tool, milling parameters, and side-wall limitation significantly affect the chip formation and characteristics of High-Aspect Ratio micro-grooves, which in turn impact the quality of machining.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Review
Automation & Control Systems
Barnabas Zoltan Balazs, Norbert Geier, Marton Takacs, J. Paulo Davim
Summary: This paper reviews recent results and developments related to micro-milling, highlighting the need for further improvement in reliability and predictability. Possible future trends and research directions in micro-milling and micro-machining areas are also discussed.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Daxiang Deng, Zhenkun Zhang, Wei Wan, Qixian Ma, Jian Sun
Summary: This study developed a unique type of omega-shaped reentrant microchannels in pure copper using a micro milling method, and comprehensively investigated the critical issues in micromilling. It was found that the restriction of top exit slot played a significant role in the formation of side burrs, and the effects of spindle speed and feed rate on side burr formation were explored.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Automation & Control Systems
Xian Wu, Mingyang Du, Jianyun Shen, Feng Jiang, Yuan Li, Li Liu
Summary: In this paper, the mechanisms of top burr formation in micro milling were analyzed, and experiments were conducted to study the effects of machining parameters on the morphology and size of top burr. It was found that the top burr is caused by unexpected material plastic side flow and unseparated chips connecting on the top side. Optimal machining strategies were suggested to minimize top burr.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Chemistry, Analytical
Zhongwei Chen, Xian Wu, Kai Zeng, Jianyun Shen, Feng Jiang, Zhongyuan Liu, Wenjun Luo
Summary: The presence of burrs on micro parts can have negative effects on dimensional accuracy and service performance. It is crucial to control the formation of exit burrs during micro milling to improve machining outcomes. Research shows that the formation of exit burrs is due to changes in material flow paths at the exit surface, and strategies such as increasing support stiffness and optimizing machining parameters can effectively control their formation.
Article
Materials Science, Multidisciplinary
Peng Liu, Yiqin Chen, Pei Zeng, Chaohui Zhang, Huigao Duan, Tinh Quoc Bui
Summary: This study demonstrates the elastocapillarity effect at sub-10-nm scale by assembling artificial high-aspect-ratio (HAR) ultrathin walls into complex patterns through designable elastocapillary. The experimental results are well explained by finite element analysis, and theoretical derivation shows that closed nanowalls are more stable than open nanowalls. This research provides an alternative post-assembly technique for forming complex structures.
MATERIALS TODAY COMMUNICATIONS
(2022)
Article
Engineering, Electrical & Electronic
A. Sravan Kumar, Sankha Deb, S. Paul
Summary: This study investigates an ultrasonic-assisted abrasive micro-deburring process that can efficiently remove burrs from high-aspect-ratio micro-pillars. The process achieves high deburring efficiency while maintaining the integrity of the micro-pillars, with burr reduction rates as high as 88.75% for Al 6061 and 90.1% for copper in a short processing time of 10 s.
JOURNAL OF MICROMECHANICS AND MICROENGINEERING
(2022)
Article
Automation & Control Systems
Qi Wang, Dazhong Wang, Yu Fang
Summary: This paper investigates the difficult-to-machine properties and tool wear issues of nickel-based high-temperature alloy Inconel 718. By comparing conventional drilling and ultrasonic-assisted drilling, it is found that ultrasonic-assisted drilling can reduce machining temperature and improve chip morphology.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Xiuqing Hao, Wenhao Xu, Mengyue Chen, Chen Wang, Jinjin Han, Liang Li, Ning He
Summary: A hybrid and successive method, NLMM, combining nanosecond laser and micro-milling, was proposed to improve the fabrication quality of HAR micro-grooves on oxygen-free copper. Compared to traditional FSMM, the NLMM method can enhance surface quality and reduce tool wear rate, successfully fabricating desired S-shaped grooves.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Article
Engineering, Mechanical
Rahul Yadav, N. D. Chakladar, Soumitra Paul
Summary: This study demonstrates through numerical modeling and experimental verification that introducing compressive residual stress on the surface of the workpiece can effectively control burr formation in micro-milling of Ti-6Al-4V, reducing burr width and height by 63%.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
Article
Materials Science, Multidisciplinary
Rahul Yadav, N. D. Chakladar, Soumitra Paul
Summary: In this study, an analytical methodology is proposed to determine the burr morphology during micro-milling process for different materials. The flow stress is calculated with strain gradient and dynamic recrystallization methods, and contact pressure and minimum chip thickness are introduced through FE simulation. The dimensions of individual burrs are obtained, and the effect of peening on burr formation is investigated, which reduces the top burr formation by 67%.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Automation & Control Systems
Yigang Sun, Shenghui Hou, Baichun Li, Hao Yu, Xiaokun Li, Yong Liu, Zhenpeng He, Fangchao Yan
Summary: To analyze and control the micro milling process, this study proposed a method combining FEM and regression analysis to simulate and analyze the cutting process of cutting edge micro-elements at different axial height positions for micro ball-end milling cutters. By combining curve equations and measurements, an accurate model was established, and multiple sets of cutting edge micro-elements of equal thickness were obtained. Through finite element simulation and regression analysis, the micro milling force prediction was achieved, and experiments showed the correctness and reliability of the numerical simulation and force prediction method.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Rahul Yadav, Nilanjan Das Chakladar, Soumitra Paul
Summary: Precision components often require micro-milling, which can result in surface defects such as burrs. A pre-treatment on the surface was found to compensate for burr formation and improve the finishing of the micro-milled component. A finite element model of the micro-milling process was developed, revealing that compressive residual stress can significantly reduce burr formation, cutting temperatures, and contact forces. The study also predicted surface residual stresses induced by micro-milling and investigated the mechanism of burr formation and cutting forces.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Aerospace
Guolong Zhao, Hongjun Xia, Yang Zhang, Liang Li, Ning He, Hans Nrgaard Hansen
Summary: A novel hybrid process of laser-induced oxidation assisted micro milling (LOMM) was proposed to address severe tool wear and poor surface quality issues during micro machining of cemented carbide. The results showed that LOMM improved material machinability, achieved superior machined surface quality and dimensional accuracy compared to conventional micro milling (COMM). The tool wear forms in LOMM were coating spalling and slight tool nose breakage, leading to significantly prolonged tool life.
CHINESE JOURNAL OF AERONAUTICS
(2021)
Article
Chemistry, Multidisciplinary
Haijun Zhang, Shijin Lu, Chunyu Zhang, Guo Li, Fei Teng, Junjie Zhang, Tao Sun
Summary: The paper investigates the tool chatter behavior and its correlation with the machined surface morphology in the ultra-precision diamond micro-milling of a copper workpiece. Through a combination of finite element simulations and experimental validations, the research provides a theoretical basis for understanding the origination of tool chatter and the rational selection of machining parameters.
APPLIED SCIENCES-BASEL
(2022)