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Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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In these days one of the most important field of interest lies in the manufacturing of miniaturized parts. The economical and flexible alternative for production in small and medium lot sizes is machining with miniature, fine-grained carbide end mill. The experimental research and analytical observations of the authors in connection with material structural aspects of micro scaled chip removal and the effects of the very thin micro milling tool are described in this paper.