The process of metal and alloy micro-milling: an analytical review

Abstract

The demand for miniature, high-precision products is growing rapidly in many industries, which is driving the need for efficient manufacturing technologies. Micromilling is the most universal process for micromachining of metals and alloys. Therefore, the study of micromilling processes to increase the efficiency of machining miniature structural elements of products is an important issue for the current level of manufacturing technologies. The article presents an analytical review of modern scientific research on the process of micromilling of metals and alloys. The basic requirements for micromilling machines, their types and technical parameters are described. Typical micromilling designs, tool materials for their manufacture, and types of wear-resistant coatings used are discussed. The article provides manufacturers' recommendations on the purpose of micromilling conditions for various materials. The article explains the relationship between the effect of the minimum thickness of undeformed chips and the value of the kinematic rake angle and the scale effect with variations in cutting forces. The article discusses the peculiarities of chip formation during micromilling, namely the mechanism of chip removal at different thicknesses of the undeformed chips. The article highlights possible technical difficulties encountered during the cutting process and summarises recommendations for their solution and efficient micromilling of metals and alloys.

Keywords

• microcutting
• cutting modes
• scale effect
• mechanism of chip formation