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Micromachines
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Advances in Micro-Milling
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Advances in Micro-Milling

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D：Materials and Processing".

Deadline for manuscript submissions: closed (31 January 2023) | Viewed by 10096

Special Issue Editors

Dr. Yixuan Feng

E-Mail Website
Guest Editor
Department of Chemical and Biomolecular Engineering, Rice University, Houston, TX 77005, USA
Interests: advanced manufacturing; hydraulic fracturing
Special Issues, Collections and Topics in MDPI journals
Dr. Man Zhao

E-Mail Website
Guest Editor
School of Mechanical and Automotive Engineering, Shanghai University of Engineering and Science, Shanghai 201620, China
Interests: advanced manufacturing; microstructure evolution; residual stress
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Xiaohong Lu

E-Mail Website
Guest Editor
School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
Interests: precision machining; micro-milling; modeling; process simulation; FSW
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

With the increasing demand for micro-structure/parts in aerospace, biomedical, microelectronics, and other industries, micro-milling technology, which uses a high-frequency spindle together with cutting tools with diameters smaller than 1 mm, has become common because of its machining accuracy and machining capabilities.

In the micro-milling process, mechanical loading and thermal loading result in material microstructure evolution, which significantly affect material macro properties and the distribution of residual stress, including recrystallization and grain growth, crystallographic texture evolution, dislocation density evolution, and phase transformation. On the other hand, as a key evaluation index of the surface integrity, residual stress induced in micro-milling is important, and it is imperative to understand and control it to improve the dimension accuracy and surface finish of the workpiece.

This Special Issue is devoted to advances in the scientific understanding of micro-milling, mainly in metals, but also in composites, ceramics, and other structural/functional materials. We welcome research papers, short communications, and review articles that focus on research, design, manufacture, performance validation, and application of high-precision machining, including fundamental and applied research and development in micro-milling processes and advanced measurement science. The scope includes micro-milling systems and supporting metrology over a range of micro scales.

We look forward to receiving your submissions.

Dr. Yixuan Feng
Dr. Man Zhao
Prof. Dr. Xiaohong Lu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Micromachines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • micro-milling
  • modeling and simulation
  • system and measurement
  • scale effect
  • surface integrity
  • residual stress
  • microstructure evolution

Related Special Issue

Published Papers (6 papers)

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Research

16 pages, 3886 KiB  
Article
Process Development for Batch Production of Micro-Milling Tools Made of Silicon Carbide by Means of the Dry Etching Process
by Christian-G. R. Wittek, Lukas Steinhoff, Selina Raumel, Michael Reißfelder, Folke Dencker and Marc C. Wurz
Micromachines 2023, 14(3), 580; https://doi.org/10.3390/mi14030580 - 28 Feb 2023
Cited by 1 | Viewed by 1539
Abstract
Downsized and complex micro-machining structures have to meet quality requirements concerning geometry and convince through increasing functionality. The development and use of cutting tools in the sub-millimeter range can meet these demands and contribute to the production of intelligent components in biomedical technology, [...] Read more.
Downsized and complex micro-machining structures have to meet quality requirements concerning geometry and convince through increasing functionality. The development and use of cutting tools in the sub-millimeter range can meet these demands and contribute to the production of intelligent components in biomedical technology, optics or electronics. This article addresses the development of double-edged micro-cutters, which consist of a two-part system of cutter head and shaft. The cutting diameters are between 50 and 200 μm. The silicon carbide cutting heads are manufactured from the solid material using microsystem technology. The substrate used can be structured uniformly via photolithography, which means that 5200 homogeneous micro-milling heads can be produced simultaneously. This novel batch approach represents a contrast to conventionally manufactured micro-milling cutters. The imprint is taken by means of reactive ion etching using a mask made of electroplated nickel. Within this dry etching process, characteristic values such as the etch rate and flank angle of the structures are critical and will be compared in a parameter analysis. At optimal parameters, an anisotropy factor of 0.8 and an etching rate of 0.34 µm/min of the silicon carbide are generated. Finally, the milling heads are diced and joined. In the final machining tests, the functionality is investigated and any signs of wear are evaluated. A tool life of 1500 mm in various materials could be achieved. This and the milling quality achieved are in the range of conventional micro-milling cutters, which gives a positive outlook for further development. Full article
(This article belongs to the Special Issue Advances in Micro-Milling)
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14 pages, 4682 KiB  
Article
Facile Production Method of PbS Nanoparticles via Mechanical Milling of Galena Ore
by Bety S. Al-Saqarat, Ahmed Al-Mobydeen, Ahmed N. AL-Masri, Muayad Esaifan, Imad Hamadneh, Iessa Sabbe Moosa and Ehab AlShamaileh
Micromachines 2023, 14(3), 564; https://doi.org/10.3390/mi14030564 - 27 Feb 2023
Cited by 3 | Viewed by 1443
Abstract
In this research, some physical properties such as the density, specific heat capacity, and micro-hardness of galena ore lumps purchased from the public market were determined. The microscopic study, using the scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS), confirmed that [...] Read more.
In this research, some physical properties such as the density, specific heat capacity, and micro-hardness of galena ore lumps purchased from the public market were determined. The microscopic study, using the scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS), confirmed that the as-received galena ore was mostly lead sulfide (PbS). The XRD pattern of the galena powder also elucidated that all the peaks were assigned to PbS. In addition, the as-received galena was roughly crushed, and fine-milled using a high-vibration milling machine with tungsten carbide rings. Nanoscale particles of about 90 nm were produced in a very short milling time of around 15 min. The obtained nanoscale powder was well investigated in the SEM at low and high magnifications to assess the exact range of particle size. Meanwhile, the SEM was employed to investigate the microstructure of sintered samples, where a part of the milled galena powder was compacted and sintered at 700 °C for 2 h. Again, the result of this investigation proved the formation of PbS with even smaller grain size compared with the grain size of the starting galena ore. A high relative sinter density of approximately 97% for galena powder was achieved by sintering under vacuum. Full article
(This article belongs to the Special Issue Advances in Micro-Milling)
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16 pages, 7753 KiB  
Article
Influence of Size Effect in Milling of a Single-Crystal Nickel-Based Superalloy
by Luis Soriano Gonzalez, Fernanda Medina Aguirre, Sein Leung Soo, Richard Hood and Donka Novovic
Micromachines 2023, 14(2), 313; https://doi.org/10.3390/mi14020313 - 26 Jan 2023
Cited by 3 | Viewed by 1446
Abstract
This paper details an experimental investigation on the influence of the size effect when slot-milling a CMSX-4 single-crystal nickel-based superalloy using 1 mm- and 4 mm-diameter TiAlN-coated tungsten carbide (WC) end-mills. With all tools having similar cutting-edge radii (re) of ~6 [...] Read more.
This paper details an experimental investigation on the influence of the size effect when slot-milling a CMSX-4 single-crystal nickel-based superalloy using 1 mm- and 4 mm-diameter TiAlN-coated tungsten carbide (WC) end-mills. With all tools having similar cutting-edge radii (re) of ~6 µm, the feed rate was varied between 25–250 mm/min while the cutting speed and axial depth of cut were kept constant at 126 m/min and 100 µm, respectively. Tests involving the Ø 4 mm end-mills exhibited a considerable elevation in specific cutting forces exceeding 500 GPa, as well as irregular chip morphology and a significant increase in burr size, when operating at the lowest feed rate of 25 mm/min. Correspondingly for the Ø 1 mm micro-end-mills, high levels of specific cutting forces up to ~1000 GPa together with severe material ploughing and grooving at the base of the machined slots were observed. This suggests the prevalence of the size effect in the chip formation mechanism as feed per tooth/uncut chip thickness decreases. The minimum uncut chip thickness (hmin) when micromilling was subsequently estimated to be less than 0.10 re, while this increased to between 0.10–0.42 re when machining with the larger Ø 4 mm tools. Full article
(This article belongs to the Special Issue Advances in Micro-Milling)
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23 pages, 9052 KiB  
Article
A Ti-6Al-4V Milling Force Prediction Model Based on the Taylor Factor Model and Microstructure Evolution of the Milling Surface
by Siyuan Zhu, Man Zhao, Jian Mao and Steven Y. Liang
Micromachines 2022, 13(10), 1618; https://doi.org/10.3390/mi13101618 - 27 Sep 2022
Cited by 3 | Viewed by 1388
Abstract
In this paper, a milling force prediction model considering the Taylor factor is established, and the Ti-6Al-4V milling force predicted by the model under different milling parameters is presented. In the study, the milling experiment of Ti-6Al-4V was carried out, the milling force [...] Read more.
In this paper, a milling force prediction model considering the Taylor factor is established, and the Ti-6Al-4V milling force predicted by the model under different milling parameters is presented. In the study, the milling experiment of Ti-6Al-4V was carried out, the milling force was collected by the dynamometer, and the microstructure evolution of the milling surface before and after milling was observed by EBSD. Through the comparative analysis of the experimental results and the model prediction results, the reliability of the prediction model proposed in this study was verified, and the influences of the milling parameters on the milling force were further analyzed. Finally, based on the EBSD observation results, the effects of the milling parameters on the microstructure evolution of the milling surface were studied. The results show that both the tangential milling force and normal milling force increase with the increase in the milling depth and feed rate. Among the milling parameters selected in this study, the milling depth has the greatest influence on the milling force. The average errors of the tangential milling force and normal milling force predicted by the milling force model are less than 10%, indicating that the milling force prediction model established in this paper considering Taylor factor is suitable for the prediction of the Ti-6Al-4V milling force. With the change in the milling parameters, the grain structure, grain size, grain boundary distribution, phase distribution, and micro-texture of the material surface change to varying degrees, and the plastic deformation of the milling surface is largely coordinated by the slip. Full article
(This article belongs to the Special Issue Advances in Micro-Milling)
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13 pages, 5053 KiB  
Article
Study on the Formation Mechanism of Cutting Dead Metal Zone for Turning AISI4340 with Different Chamfering Tools
by Shujing Wu, Dazhong Wang, Jiajia Zhang and Alexey B. Nadykto
Micromachines 2022, 13(7), 1156; https://doi.org/10.3390/mi13071156 - 21 Jul 2022
Cited by 2 | Viewed by 1622
Abstract
Tools with chamfered edges are often used in high speed machining of hard materials because they provide compelling cutting toughness and reduced tool wear. Chamfered tools are also responsible for the dead metal zone (DMZ). Through numerical simulation of orthogonal cutting with AISI [...] Read more.
Tools with chamfered edges are often used in high speed machining of hard materials because they provide compelling cutting toughness and reduced tool wear. Chamfered tools are also responsible for the dead metal zone (DMZ). Through numerical simulation of orthogonal cutting with AISI 4340 steel, this paper examines the mechanism of the DMZ, the cutting speed, the impacts of the chamfer angle, and the coefficient of friction on the generation of the DMZ. The analysis is based upon the Arbitrary Lagrangian-Eulerian (ALE) finite element method (FEM) for the continuous process of chip formation. The different chamfered angles, cutting speeds, and friction coefficient conditions are utilized in the simulation. The research demonstrates that a zone of trapped material called DMZ has been formed beneath the chamfer and serves as an effective cutting edge of the tool. Additionally, the dead metal zone DMZ becomes smaller while the cutting speed increases or the friction coefficient decreases. The machining forces rise with increasing chamfer angles, rise with increasing friction coefficients, and fall with increasing cutting speed in both the cutting and thrust directions. In this paper, the effect of different chamfering tools on AISI 4340 steel using carbide tools in the simulation environment is studied. It has certain reference significance for studying the formation mechanism of the dead zone of difficult-to-machine materials such as AISI4340 and improving the processing efficiency and workpiece surface quality. Full article
(This article belongs to the Special Issue Advances in Micro-Milling)
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11 pages, 2704 KiB  
Article
Research on the Influence of Tool Surface Texture on Cutting Performance Based on Finite Element Method
by Shujing Wu, Dazhong Wang and Jiahui Yin
Micromachines 2022, 13(7), 1091; https://doi.org/10.3390/mi13071091 - 10 Jul 2022
Cited by 3 | Viewed by 1522
Abstract
As research progresses, the surface texture tool can significantly reduce the cutting heat and cutting force. However, the tool surface texture width, depth, and spacing also have an impact on the cutting performance. Using the Taguchi method and finite element analysis, the changing [...] Read more.
As research progresses, the surface texture tool can significantly reduce the cutting heat and cutting force. However, the tool surface texture width, depth, and spacing also have an impact on the cutting performance. Using the Taguchi method and finite element analysis, the changing laws of cutting temperature, pressure, stress distribution, and cutting force were studied. The results showed that the tool texture width had the greatest influence on the cutting performance, followed by the tool texture depth and spacing. The increase of tool texture width lead to the decrease of cutting temperature, stress distribution, and cutting force, while the effect of texture depth on cutting stress distribution was more significant. Cutting performance could be improved by optimizing the texture size and structure of the cutting tool. This research has theoretical significance for improving the cutting performance of cutting tools. Full article
(This article belongs to the Special Issue Advances in Micro-Milling)
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