This paper investigates the characteristics of a micro-scale end-milling process using the electro-hydro-dynamic (EHD) spray lubrication with chilly air. A new hybrid cooling and lubrication system was developed by integrating EHD spray and chilly air supply modules. In the experiments, the milling forces and burr formation are observed according to varying cooling and lubrication conditions. It is demonstrated that the developed new hybrid cooling and lubrication system can reduce milling forces and burrs significantly.

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