Advances in Multidisciplinary Engineering
Ultra High-Speed Micro-Milling of Aluminum Alloy
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Small precision parts with miniaturized features are increasingly used in components such as sensors, micromedical devices, micro-fuel cells, and others. Mechanical micromachining processes, e.g., turning, drilling, milling and grinding are often used for fabrication of miniaturized components. The small micro-tools (50 μm to 500 μm diameter) used in micromachining limit the surface speeds achieved at the cutting point, unless the rotational speeds are substantially increased. Although the cutting speeds increase to 240 m/min with larger diameter tools (e.g., 500 μm) when using the highest available spindle speed of 150,000 rpm, the cutting speed with the smaller 50 μm tools is...