Tool geometry study in micromachining

With the trend towards miniaturization, micromachining becomes more and more important in fabricating micro parts. Investigations have shown that unpredictable tool life and premature tool failure present a serious concern in micromachining. To further develop the process, a systematic study of various types of tool geometry has been carried out. The tool failure modes and the ways in which tool life can be improved were also studied. Experimental results show that the tool tip rigidity of the semi circle-based (D-type) end-mills is much higher than that of the two-flute (commercial type) end-mills, and the machining quality with the D-type tools is better than that of the triangle-based ( -type) end-mills. The tool breakage of end-milling operations simulated using real tool geometry is in good agreement with experimental data. Both the experimental study and FEM analysis have shown that the D-type end-mills are more suitable for micromachining. (Some figures in this article are in colour only in the electronic version)