Advances in micro cutting tool design and fabrication

Abstract

Microcutting is a precision technology that offers flexible fabrication of microfeatures or complex three-dimensional components with high machining accuracy and superior surface quality. This technology may offer great potential as well as advantageous process capabilities for the machining of hard-to-cut materials, such as tungsten carbide. The geometrical design and dimension of the tool cutting edge is a key factor that determines the size and form accuracy possible in the machined workpiece. Currently, the majority of commercial microtools are scaled-down versions of conventional macrotool designs. This approach does not impart optimal performance due to size effects and associated phenomena. Consequently, in-depth analysis and implementation of microcutting mechanics and fundamentals are required to enable successful industrial adaptation in microtool design and fabrication methods. This paper serves as a review of recent microtool designs, materials, and fabrication methods. Analysis of tool performance is discussed, and new approaches and techniques are examined. Of particular focus is tool wear suppression in the machining of hard materials and associated process parameters, including internal cooling and surface patterning techniques. The review concludes with suggestions for an integrated design and fabrication process chain which can aid industrial microtool manufacture.

Challenges on machining characteristics of natural fiber-reinforced composites – A review

“…Tool materials which can meet these demands are only a limited choice. 151 Also conventional processes generate various forms of wastages in the form of solid, liquid, and gaseous wastages which result in serious occupational health and environmental issues during the machining process. Hence, environmental friendly non-conventional machining processes are essential.…”

Design and Accuracy Analysis of a Micromachine Tool with a Co-Planar Driving Mechanism

“…The development trend of light, thin, short, and small consumer products has led to the demand for micromachining processes, which require highly accurate, versatile, and stable micromachine tools [1][2][3][4]. The development of advanced micromachining technology to produce high-quality micro products with excellent dimensional tolerances is required.…”

Experimental Study on the Minimum Undeformed Chip Thickness Based on Effective Rake Angle in Micro Milling

“…In recent years, the requirements for miniaturization of part and device have become increasing with the rapid development of many fields, such as communications, electronics, biomedicine, etc. With the fabrication of micro cutting tool, micro milling has been widely used to manufacture micro parts due to the obvious advantages, such as high efficiency and quality [ 1 , 2 , 3 ]. However, compared with macro milling, micro milling process presents some unique characteristics which greatly affect the machining quality.…”