Review of dynamic issues in micro-end-milling

In recent years, the miniaturization of products has become a trend all over the world. Besides conventional precision manufacturing technology and micro-electro-mechanical systems (MEMS), micro/meso mechanical manufacturing (M4) technology is regarded as another choice for an effective method to fabricate micro complicated 3D features, which need special attention paid to. In micro-end-milling machining, the stiffness of a micro-end-milling machine tool is somewhat lower, due to the size effect of material, and also, obviously, the ploughing condition and the quite slender end-milling tool. Thus, the stability of a micro-end-milling machine is very weak. This paper reviews the state-of-the-art of studying chip formation and dynamic problems in micro-end-milling, and discusses the possible future works in this field.

[1]  Yazhou Sun MICRO-SCALE AND MESO-SCALE MECHANICAL MANUFACTURING , 2004 .

[2]  Kazuya Kato,et al.  Generation of Sculptured Surfaces by Means of an Ultraprecision Milling Machine , 1993 .

[3]  William J. Endres,et al.  A Dual-Mechanism Approach to the Prediction of Machining Forces, Part 1: Model Development , 1995 .

[4]  Shuliang Dong,et al.  Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining , 1996 .

[5]  L. Geng,et al.  Ultraprecision machining of SiCw/Al composites , 1993 .

[6]  T. Hirano,et al.  Microfactories; new applications of micromachine technology to the manufacture of small products , 1997 .

[7]  H. Weule,et al.  Micro-Cutting of Steel to Meet New Requirements in Miniaturization , 2001 .

[8]  Ibrahim N. Tansel,et al.  Tool wear estimation in micro-machining.: Part II: neural-network-based periodic inspector for non-metals , 2000 .

[9]  Yusuf Altintas,et al.  Mechanism of Cutting Force and Surface Generation in Dynamic Milling , 1991 .

[10]  Lothar Bohn,et al.  Microstructure grooves with a width of less than 50 μm cut with ground hard metal micro end mills , 1999 .

[11]  Chang Ju Kim,et al.  A static model of chip formation in microscale milling , 2004 .

[12]  Takeshi Yoneyama,et al.  Micro cutting in the micro lathe turning system , 1999 .

[13]  William J. Endres,et al.  A dual-mechanism approach to the prediction of machining forces, part 2: Calibration and validation , 1995 .

[14]  Chi Fai Cheung,et al.  A theoretical and experimental investigation of surface generation in diamond turning of an Al6061/SiCp metal matrix composite , 2001 .

[15]  Dieter Spath,et al.  Einfluss des Wärmebehandlungszustands auf die Mikrozerspanbarkeit von Stählen. Diskussion , 2000 .

[16]  Ibrahim N. Tansel,et al.  Tool wear estimation in micro-machining.: Part I: tool usage–cutting force relationship , 2000 .

[17]  D. Choi,et al.  A Study of the Micro Pole Structure Fabrication and Application Technology by Micro End-Milling Process , 2004 .

[18]  John W. Sutherland,et al.  An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems , 1986 .

[19]  Ibrahim N. Tansel,et al.  Modeling micro-end-milling operations. Part I: analytical cutting force model , 2000 .

[20]  D. W. Wu,et al.  A New Approach of Formulating the Transfer Function for Dynamic Cutting Processes , 1989 .

[21]  Young-bong Bang,et al.  5-axis micro milling machine for machining micro parts , 2005 .

[22]  Ibrahim N. Tansel,et al.  Micro-end-milling—III. Wear estimation and tool breakage detection using acoustic emission signals , 1998 .

[23]  Shoichi Shimada,et al.  Molecular Dynamics Analysis as Compared with Experimental Results of Micromachining , 1992 .

[24]  Craig R. Friedrich,et al.  Development of the Micromilling Prolcess for High-Aspect-Ratio Microstructures , 1996 .

[25]  Craig R. Friedrich,et al.  Micrometer-scale machining: tool fabrication and initial results , 1996 .

[26]  P. Cohen,et al.  Machinability of gray iron—Mechanics of chip formation , 1999 .

[27]  Chang-Ju Kim Mechanisms of chip formation and cutting dynamics in the micro-scale milling process. , 2004 .

[28]  Martin B.G. Jun,et al.  Cutting Mechanisms and Their Influence on Dynamic Forces, Vibrations and Stability in Micro-Endmilling , 2004 .

[29]  Hiroaki Tanaka,et al.  Feasibility Study on Ultimate Accuracy in Microcutting Using Molecular Dynamics Simulation , 1993 .

[30]  Ibrahim N. Tansel,et al.  Modeling micro-end-milling operations. Part III: influence of tool wear , 2000 .

[31]  A. Kumar,et al.  Micro milling of pure copper , 2001 .

[32]  R. DeVor,et al.  Microstructure-Level Force Prediction Model for Micro-Milling of Multi-Phase Materials , 2001, Manufacturing Engineering.

[33]  Jost Goettert,et al.  Direct fabrication of deep x-ray lithography masks by micromechanical milling , 1998 .

[34]  Ibrahim N. Tansel,et al.  Modeling micro-end-milling operations. Part II: tool run-out , 2000 .

[35]  Mohamed A. Elbestawi,et al.  An Enhanced Dynamic Model in Turning Including the Effect of Ploughing Forces , 1997 .

[36]  Craig R. Friedrich,et al.  Rapid fabrication of molds by mechanical micromilling: process development , 1995, Photonics West - Micro and Nano Fabricated Electromechanical and Optical Components.

[37]  Y. Ohbuchi,et al.  Finite Element Modeling of Chip Formation in the Domain of Negative Rake Angle Cutting , 2003 .

[38]  Hiroyasu Iwabe,et al.  Effect of tool stiffness upon tool wear in high spindle speed milling using small ball end mill , 2001 .

[39]  Ibrahim N. Tansel,et al.  Micro-end-milling—I. Wear and breakage , 1998 .