Precision micro-milling process: state of the art

Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

A novel hybrid technique to fabricate silicon-based micro-implants with near defect-free quality for neuroprosthetics application

This paper introduces a new hybrid microfabrication technique which combines ultra-precision micro-milling and a ductile sacrificial material deposition process to fabricate a silicon-based implant for neuroprosthetics applications with near defect-free quality at several hundreds of micrometres in thickness. The sacrificial materials can influence the quality of silicon during machining. The cutting mechanism and feasibility of the hybrid technique are studied by molecular dynamics (MD) simulations and experiments. Due to the complexity of modelling PMMA and SU-8 structures in MD environment, only copper was modelled as the simulation is intended to understand the performance of using a ductile sacrificial layer structure in silicon machining. MD analysis shows that the reduced stress intensity and subsurface damage were mainly attributed to workpiece plasticity enhancement, where its mechanism was contributed by better deformability of the ductile sacrificial layer and enhanced thermal softening from the heat generated by the high interfacial stress between the sacrificial layer and silicon substrate. Despite the MD simulation and experiment having different machining scale in terms of cutting parameters, phenomenal behaviours of the cutting performance when observed under the experimental conditions are in good agreement with simulation. Experimental verification shows that near defect-free quality was achieved at large cutting depth of 150 μm when silicon is coated either with PMMA or SU-8. An exemplary implant structure was also fabricated to better demonstrate the hybrid technique's capability. In addition, the hybrid technique will be beneficial for low volume high customisation applications as it is a serial process.

MicroEye : A low-cost online tool wear monitoring system with modular 3D-printed components for micro-milling application

Tool detachment during the machining process is often required by many image-based tool wear monitoring (TWM) systems. Tool detachment prevents the online mode of the wear measurement, extends the machining time, and contributes to measurement inaccuracy. Other alternatives of the image-based TWM systems have been developed with the image-acquisition device located statically near the tool position without the requirement for the tool detachment. However, due to its proximity to the machining site, the image-acquisition device may experience obstruction from the workpiece chips and the splash of coolant fluid during the machining process, resulting in non-optimal TWM. This article presents MicroEye - an online image-based TWM system with modular 3D-printed components to overcome the two problems. MicroEye offers great flexibility in its operation through the use of an active 6-DOF (degree of freedom) robotics arm with a camera at the end-effector. MicroEye does not require tool detachment to perform tool wear monitoring and can be safely placed outside the machining area. MicroEye is the first open-sourced, 3D-printed components and active dynamic-type TWM system for the application of micro-milling. MicroEye can be built at a low-cost (approximately US$ 872, including the camera). MicroEye is suitable for various micro-milling sites, from laboratory scale to middle-low workshop.

Optimal tool design in micro-milling of difficult-to-machine materials

The limitations of significant tool wear and tool breakage of commercially available fluted micro-end mill tools often lead to ineffective and inefficient manufacturing, while surface quality and geometric dimensions remain unacceptably poor. This is especially true for machining of difficult-to-machine (DTM) materials, such as super alloys and ceramics. Such conventional fluted micro-tool designs are generally down scaled from the macro-milling tool designs. However, simply scaling such designs from the macro to micro domain leads to inherent design flaws, such as poor tool rigidity, poor tool strength and weak cutting edges, ultimately ending in tool failure. Therefore, in this article a design process is first established to determine optimal micro-end mill tool designs for machining some typical DTM materials commonly used in manufacturing orthopaedic implants and micro-feature moulds. The design process focuses on achieving robust stiffness and mechanical strength to reduce tool wear, avoid tool chipping and tool breakage in order to efficiently machine very hard materials. Then, static stress and deflection finite element analysis (FEA) is carried out to identify stiffness and rigidity of the tool design in relation to the maximum deformations, as well as the Von Mises stress distribution at the cutting edge of the designed tools. Following analysis and further optimisation of the FEA results, a verified optimum tool design is established for micro-milling DTM materials. An experimental study is then carried out to compare the optimum tool design to commercial tools, in regards to cutting forces, tool wear and surface quality.

Optimizing CNC milling parameters for manufacturing of ultra-sharp tip microneedle with various tip angles

Microneedle technology has emerged as an advanced method for transdermal drug delivery, which focuses on diverse fabrication techniques to develop microneedles with various models and geometries. This study explores the application of Computer Numerical Control (CNC) milling technology to create microneedle master molds with extremely sharp tips. We examined the effects of two key machining parameters, feed rate and ramp angle, on the tip sharpness of the microneedles. Our results showed that increasing both the feed rate and ramp angle could significantly reduce machining time. However, a higher feed rate also led to larger tip diameters and notable tip defects. Conversely, changes in the ramp angle at a constant feed rate had minimal impact on tip size. We identified an optimal condition balancing cutting time and tip sharpness at a feed rate of 100 mm/min and a ramp angle of 1.5°. Additionally, we assessed the CNC's capability to produce needles with different tip angles. The findings confirm that needles with varying tip angles maintained tip diameters below 10 μm, with needles having a 50° tip angle exhibiting the sharpest tips at approximately 3.3 μm. Further compression, insertion and diffusion tests were conducted to evaluate the performance of needles with different geometries.