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Micromilling: Material microstructure effects

Article in Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture
November 2006
DOI: 10.1243/09544054JEM683

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1807

Micromilling: material microstructure effects


K B Popov1*, S S Dimov1, D T Pham1, R M Minev1, A Rosochowski2, and L Olejnik3
1
Manufacturing Engineering Centre, Cardiff University, Cardiff, UK
2
Design, Manufacture, and Engineering Department, University of Strathclyde, Glasgow, UK
3
Institute of Materials Processing, Warsaw University of Technology, Warsaw, Poland
The manuscript was received on 10 July 2006 and was accepted after revision for publication on 27 July 2006.

DOI: 10.1243/09544054JEM683

Abstract: Micromilling is one of the technologies that is currently widely used for the
production of microcomponents and tooling inserts. To improve the quality and surface
finish of machined microstructures the factors affecting the process dynamic stability should
be studied systematically. This paper investigates the machining response of a metallurgically
and mechanically modified material. The results of micromilling workpieces of an Al 5000
series alloy with different grain microstructures are reported. In particular, the machining
response of three Al 5083 workpieces whose microstructure was modified through a severe
plastic deformation was studied when milling thin features in microcomponents. The effects
of the material microstructure on the resulting part quality and surface integrity are
discussed and conclusions made about its importance in micromilling. The investigation has
shown that through a refinement of material microstructure it is possible to improve
significantly the surface integrity of the microcomponents and tooling cavities produced by
micromilling.

Keywords: micromilling, material microstructure, grain size effects

1 INTRODUCTION stability of the process should be investigated


systematically.
The current trend for product miniaturization fuels The typical cutting conditions in micromilling
the demand for new microengineering technologies imply that the material removal process is governed
that are suitable for manufacture of mesoscale com- by the interfacial interaction between the cutting
ponents incorporating microfeatures. Micromilling edge and the workpiece material. Because of this,
is one of these technologies that is currently being the microstructure of the workpiece can play a
widely used for the production of microstructures fundamental role in the cutting process [2].
and tooling inserts for microinjection moulding The effects of material properties on the micro-
and hot embossing. In particular, important appli- cutting mechanism are considered extremely impor-
cation areas of this technology are the manufacture tant. The effects of the high-frequency vibrations
of microparts for watches, keyhole surgery, housings that could occur during the micromilling process
for microengines, tooling inserts for fabrication of are investigated in reference [1]. A conclusion is
microfilters, and housings and packaging solutions made that the quality of the machined microstruc-
for micro-optical and microfluidics devices. A com- tures is highly dependent on the milling strategies
mon challenge across all these applications is the employed. This research could be considered as a
machining of thin features [1]. To machine reliable continuation of the experimental study in reference
microcomponents with thin features and improve [1]. In particular, the milling strategies that were
their surface finish, the factors affecting the dynamic optimized for machining thin features by Popov
et al. were applied in this research to investigate
the effects of the workpiece microstructure on part
*Corresponding author: Manufacturing Engineering Centre, quality and surface integrity.
Cardiff University, Queens Building, The Parade, Newport Other researches reported that the integrity of
Road, Cardiff CF24 3AA, UK. email: scekbp@cf.ac.uk the machined surfaces was highly dependent on

JEM683  IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1808 K B Popov, S S Dimov, D T Pham, R M Minev, A Rosochowski, and L Olejnik

the number of passes and the depth of the cuts [3]. during the cutting, the dislocation density increases
Especially, it was found that the depth of the cuts owing to the formation of new dislocations and
had increased the burnishing caused by the friction dislocation multiplication.
between the generated surface and the tool flank It is considered that refinements of the grain
face. This contributed to the recovery of the elastic structure could lead to more favourable conditions
strains of the crystal grains and their subsequent during cuttermaterial interactions and thus result
stress relief. Also, it was suggested that a quantifi- in a better machining response, especially at the
cation of the resulting surface integrity after the microscale. For example, when cutting simulta-
machining operations might offer important infor- neously a larger number of grains, chatter vibrations
mation about the component performance. It due to crystallographic changes can be attenuated.
was found that the depth of the damaged layer The material refinement also increases grain bound-
in non-ferrous metals, e.g. Al and Cu, machined aries that disrupt the motion of dislocations through
with very sharp cutting tools could range from 1 a material. Therefore, reducing the crystallite size is
up to 17 mm. However, the effects that a modifica- a common way to improve strength, often without
tion of the workpiece material, both metallurgically any sacrifice in toughness.
and mechanically, could have on the machining In this research, the machining response of an
response in micromilling were not investigated. ultra fine grained (UFG) metal is studied. UFG
The aim of the paper is to investigate the machin- metals, also known as nanocrystalline metals or
ing response of metallurgically and mechanically nanometals, have grain sizes of 0.11 mm. This is
modified materials. The results of machining three about 100 times less compared to the grain size of
workpieces of the Al 5000 series alloy with different the material in its initial state before undergoing
grain sizes are reported. The effects of the material any refinement of its microstructure.
microstructure on the resulting surface integrity
are discussed and conclusions made about their 2.2 Material processing
importance in machining microcomponents.
A number of techniques exist for creating UFG
metals, e.g. compaction of nanopowders, crystalliza-
tion of amorphous materials, electrodeposition, and
2 MATERIAL MICROSTRUCTURE AND severe plastic deformation (SPD). In this research,
PROCESSING the machining response of a metal created through
SPD is employed. By applying this refinement tech-
2.1 Grain size effects nique, dislocation bands are created that subdivide
When performing metal cutting, it is important to original coarse grains into much smaller grains.
study the chip formation in order to understand the The SPD technology enables processing of all
surface generation mechanism. The crystalline tex- kinds of metal using a new class of metal-working
ture of the material resulting from its processing process that does not change the shape of the metal
could lead to variations of the chip thickness. billet [5]. One of these new processes, equal channel
In addition, such variations could be caused by angular pressing (ECAP), is employed in this study to
changes in shear angle from grain to grain owing to create a UFG metal. In particular, this is achieved
varying material properties such as elastic modulus by forcing a billet material through an intersection
(E). However, it should be said that the anisotropic of two channels having the same cross-section
cutting conditions resulting from these effects may as shown in Fig. 1. Simple shear occurring in the
be attenuated or even eliminated by refining the diagonal plane at such an intersection leads to grain
grain structure or strain hardening the material
before machining.
The defects in the crystalline structure strongly
influence the material properties and directly affect
the metal cutting conditions. In micromilling, during
the cutting process microcracks along the grain
boundaries develop and also dislocation slips occur
in the metals crystal structure. The specific proces-
sing energy required to initiate the chip formation
depends directly on the ability of metals to produce
dislocation slips. By enhancing the mechanical
strength of metals the mobility of the dislocations
is reduced and higher cutting forces will be required
to move a sharp tool through the material [4]. Also, Fig. 1 Equal channel angular pressing (ECAP)

Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM683  IMechE 2006
Micromilling: material microstructure effects 1809

refinement. To achieve a uniform and stable UFG chord and the mean vertical chord of the grains.
structure, the billet is passed several times through Usually, such an intensive plastic deformation
an ECAP die and rotated about its axis, e.g. by 90 , facilitates dissolution of metastable phases and
between any two consecutive passes. also precipitation of stable phases in aluminium
alloys, for example b and T phases. The disloca-
tion multiplication leads to intensive formation
3 EXPERIMENTAL SET-UP
of loops and pile-ups that together with the preci-
pitations formed subgrain boundaries. To reveal
3.1 Material
the subgrain structure (subgrains have grain
In this research, three different workpieces of boundary misorientation angles less than 15 ) of
AlMg4.5Mn alloy, with ISO designation Al 5083, the material, the test piece was etched. The size
were used to assess the effects of material micro- of the subgrains was estimated to be in the order
structure on part quality when micromilling thin of 2.5 mm
features. Al 5083 was selected owing to the capabil- 3. UFG Al 5083. To create the UFG workpiece, the
ities of the available ECAP machine set-up. The material underwent the following processing.
material is a non-heat-treatable alloy, which can Square samples, with dimensions 8 mm
only be hardened by plastic deformation. Prior 8 mm 46 mm, were cut out from the CP bar,
to micromilling its microstructure was modified lubricated, and subjected to ECAP at 180  C. Plas-
metallurgically and mechanically. In particular, the tic strain generated during one ECAP pass was
following three workpieces were used in this experi- approximately 1.15. The process was repeated
mental study. four times, with samples being rotated by 90
between consecutive passes [6, 7]. After the four
1. As received (AR) Al 5083. In its initial state the
ECAP passes the size of the grains
material was in the form of a 20 mm diameter
was significantly reduced, as shown in Fig. 3.
bar that was annealed. The bar was produced
Figure 4 presents the grain size distribution for
through hot extrusion and then annealed at
the UFG sample. The sizes range from 0.3 to
540  C. The microstructure of the annealed mate-
2.7 mm. However, a predominate number of
rial was non-uniform across the bar and the smal-
the grains, approximately 75 per cent of them,
lest grains of approximately 200 mm were located
were within the narrow range of 0.30.8 mm, with
close to its centre. Figure 2(a) shows a micrograph
an average value of 0.6 mm. This represents an
of the AR Al 5083.
almost 103 times reduction of the grain sizes in
2. Conventionally processed (CP) Al 5083. The
comparison with AR Al 5083. In addition, the sizes
second workpiece was strained to 0.9 by redu-
of the UFGs are almost five times smaller than the
cing the diameter of the AR bar from 20 to 13 mm
subgrains of the CP sample.
by forward extrusion at room temperature. After
the extrusion process, the longitudinal cross-sec- The Vickers microhardness (MHV) of the three
tion of the sample was inspected. The intensive workpieces was measured using a 50g indentation
plastic deformation resulted in significant aniso- load and 136 diamond pyramid, according to
tropic changes in the structure (Fig. 2(b)). The ASTM E384. The results are shown in Fig. 5. The
micrograph shows that the size of the primary hardness of the UFG sample measured in the A and
grains was approximately the same as that for B planes did not show any differences to indicate
the AR bar but elongated along the extrusion the existence of a structural anisotropy, while the
axis, with an anisotropy factor of 6. This factor CP and AR samples exhibited up to a 5 per cent
represents the ratio between the mean horizontal change in MHV. These results give further evidence

100 m

(a) (b)
Fig. 2 Micrographs of (a) AR and (b) CP Al 5083

JEM683  IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1810 K B Popov, S S Dimov, D T Pham, R M Minev, A Rosochowski, and L Olejnik

(a) (b)

10 m 200 nm

Fig. 3 Micrograph of UFG Al 5083 (a) in polarized light and (b) a transmission electron
microscopy (TEM) sample

800

600
ECAP
CP
Count

400

200

0
0 2 4 6 8 10 size, m

Fig. 4 Grain and subgrain size distribution of UFG and Fig. 6 Test part
CP Al 5083
Table 1 Mechanical properties of the three samples

Yield Ultimate
CP ECAP
stress strength Elongation
130 Sample Al 5083 (Mpa) (Mpa) (%)
1 Annealed 152 315 18.6
MHV0.05

2 Forward extruded 228 379 12.9


110
3 After four ECAP passes 433 472 6.1

AR

90
A B A B A B micromilling of thin features was employed in this
research. The part was designed taking into account
Fig. 5 Microhardness of the studied test pieces mea- dynamic flexibilities, natural frequencies, and mode
sured in the transverse (A) and the longitudinal shapes of common thin features and thus was
(B) cross-sections of the samples representative of the cutting conditions that could
occur when milling microstructures.
about the microstructural homogeneity achieved Machining of the test parts was carried out on a
by applying the ECAP process. KERN HSPC 2216 micromachining centre. Its poly-
Table 1 provides additional information about the mer concrete monoblock frame absorbs high-
mechanical properties of the three samples used in frequency vibrations much better than cast iron
this study. It is not difficult to see that the material frames, which is very important in micromilling.
hardness was very sensitive to the strain generated The factors affecting the performance of micro-
by the plastic deformations while tensile properties milling operations investigated in reference [8]
change more gradually. were taken into account in selecting the machin-
ing parameters in this experimental study. This
included the selection of a cutting depth that would
keep milling forces within predefined limits along
3.2 Machining set-up
the machining path. Spindle speeds and feed rates
The test part in Fig. 6 [1] that was proposed specially were chosen depending on the workpiecetool
to investigate the machining response during material combination.

Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM683  IMechE 2006
Micromilling: material microstructure effects 1811

z
800x200 m y z
Start y Area 2
pocket x
x
Area 1
End
Area 3

Area 4
(a) (b)

Fig. 7 Machining strategy

Table 2 Micromilling parameters Extrusion


Direction
Cutting Spindle Feed/ Step Step
speed speed tooth depth over
(m/min) (r/min) (mm) (mm) (mm)
15.51 33 000 0.007 0.005 0.070 Fig. 8 Profile of the UFG sample after milling in the
A plane

In addition, milling strategies that were optim-


ized for micromachining of thin features were Table 3 Roughness results
implemented in the experiments [1]. The machining
RAR
a (mm) RCP
a (mm) RUFG (mm)
of the workpieces in the three materials investigated a

included the following steps.


A(#) B(!) A(#) B(!) A(#) B(!)
1. All samples were face cut on a wire EDM 1 0.49 0.45 0.30 0.39 0.09 0.10
(electrical discharge machine). 2 0.64 0.62 0.26 0.60 0.12 0.16
2. Side A of the test part was machined entirely 3 0.47 0.51 0.46 0.56 0.16 0.18
4 0.33 0.49 0.45 0.47 0.15 0.17
using the strategy described in reference [1]. Average 0.48 0.52 0.37 0.51 0.13 0.15
3. The U-type channel and two 800 mm 200 mm Difference (%) 8 38 12
pockets on side B were then machined to their
full depth of 310 mm by applying reciprocating
plunge-cut cycles. Figure 7(a) shows the test part
were prepared from each of the available AR, CP,
after these three machining steps.
and UFG Al 5083 bars six in total. A test part with
4. Finally, the 800 mm 400 mm pocket located in
the design shown in Fig. 6 was produced from each
the centre of the part was machined, applying
of the workpieces applying the machining sequence
the milling strategy presented in Fig. 7(b). At this
outlined in section 3.2. Two test parts were
step the thin ribs of 20 mm around the pocket
machined for each material by milling workpieces
and the biggest web of the part were formed.
in two different planes, A (transverse), perpendicular
A 150 mm diameter end-mill (DIXI 7242 tool) to the extrusion direction, and B (longitudinal),
was used to mill the U-type channel and the along it. Thus, it was also possible to investigate the
800 mm 400 mm pocket. The machining parameters effects of the crystalline texture of the materials on
used to carry out the micromilling operations are the machining response. During the machining of
provided in Table 2. the six workpieces there were no noticeable differ-
To generate three-dimensional profiles and assess ences in the cutting conditions.
the resulting surface finish, the relevant areas of The generated three-dimensional profiles of the
the test parts were scanned using a surface mapping machined six parts did not show any bending of
system, Micro-XAM. The sample machined in the the ribs. One of these profiles is provided in Fig. 8,
AR material was used in the carried-out experiments but the others were almost identical. In addition,
as a reference in assessing the machining response the profiles were analysed in order to verify whether
of the CP and UFG workpieces. there were any variations in the ribs thickness in the
CC cross-section (see Fig. 6) between the samples.
Again, no variations were found. This consistency
4 EXPERIMENTAL RESULTS in thin feature quality could be explained using
milling strategies that were optimized specially for
To investigate the effects of the material microstruc- machining microribs and webs [1].
ture on part quality during micromilling, a series The surface roughnesses of four different areas
of experiments was conducted. Two workpieces on the bottom on the machined samples, as shown

JEM683  IMechE 2006 Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture
1812 K B Popov, S S Dimov, D T Pham, R M Minev, A Rosochowski, and L Olejnik

in Fig. 6, were measured over a sampling length of Severe plastic deformation and ECAP in particular
0.16 mm and a cut-off length of 0.08 mm. The sizes is a very promising method for structural refinement
of the scanned areas were chosen according to ISO and reduction of material anisotropy. However,
4288:1996 and ISO 11562:1996 [9]. The parameter further research is necessary to study the effects
used to evaluate the surface roughness was the of process configuration and process parameters
arithmetic mean roughness (Ra) because relative in order to optimize the machining response of
heights in microtopographies are more representa- different materials.
tive, especially for this type of planner surface. The
average results of all measurements are presented
in Table 3. 5 CONCLUSIONS
As expected, the surface roughness of the AR sam-
ples was the highest. At the same time the average This research investigates the effects of material
roughness of the UFG samples was approximately microstructure on part quality in micromilling. The
three and four times better than that achieved on machining response of mechanically and metallur-
the CP and AR test parts respectively. The experi- gically modified Al alloy when milling thin features
mental results show a strong relationship between in microcomponents was studied. The investigation
the material microstructure and attained surface fin- has shown that through refinement of material
ish. In addition, the grain texture and microcrystal- microstructure it is possible to improve significantly
line orientation in polycrystalline materials could the surface integrity of the machined microfeatures.
affect their machining response. In particular, the In particular, the following conclusions can be
increase in the average surface roughness of the CP made.
samples, when the milling was carried out in the B
1. The roughness of microfeatures produced by
plane (longitudinal) instead of the A plane (trans-
micromilling is highly dependent on the material
verse), exceeded 38 per cent, while for the UFG sam-
grain size. For example, the surface roughness of
ples the difference was less than 12 per cent (Table
thin features in microcomponents improved
3). The anisotropic machining response of the sam-
more than three times as a result of the reduction
ple processes by ECAP was almost the same as that
in grain sizes and material anisotropy of the Al
obtained for the AR samples, which were in the
alloy used in the experiments, from 100200 mm
most favourable annealed condition of the material.
to 0.6 mm.
This phenomenon has already been discussed in
2. A favourable crystalline texture of the material
conjunction with the structural characteristics of
with regard to the machining direction and the
the samples and was considered to be a conse-
narrow grain size distribution could lead to sur-
quence of the exceptionally good isotropy and
face roughness improvements. However, such
homogeneity of the UFG specimens. The structure
improvements are of a magnitude smaller than
refinement achieved during ECAP led to random
those achievable through a refinement of the
crystallographic grain orientation, equiaxial grain
material grain structure.
shapes, and narrow grain size distribution (see
3. There is an important correlation between the
Fig. 4).
subtle structural features of the material and the
The mechanisms of surface improvement by
post-process surface quality. The different results
refining the grain structure of AlMg alloys were
obtained after micromilling of the CP and ECAP
suggested by Jasinevicius et al. [2] and discussed
samples demonstrated that the creation of sub-
in section 2.1. In particular, the changes in the
grains on its own cannot lead to significant
machining response are associated with: (a)
improvements in surface integrity without redu-
improvements in the chip formation process due
cing the grain size and the material structural ani-
to more homogeneous grain texture and micro-
sotropy.
crystalline orientation and (b) a better toolmaterial
4. The use of optimized micromilling strategies
interaction and chatter vibration attenuation
results in the manufacture of thin features with a
because of reduced material anisotropy. The results
consistent quality. For example, the rib thickness
of this research support these assumptions and
of the machined test parts was consistent
demonstrate clearly that there is an important cor-
throughout the carried-out experiments and
relation between the isotropy/homogeneity of the
did not show any variations when using work-
material and the post-process surface quality. The
pieces with different material microstructures.
different performance of the CP and ECAP samples
shows that the creation of subgrains on its own Further research is required to benefit from the
cannot lead to significant improvements in surface grain size effects in manufacturing microcompo-
integrity without a reduction in grain size and nents in a range of microengineering applications.
material structural anisotropy. For example, the use of UFG brass as a material

Proc. IMechE Vol. 220 Part B: J. Engineering Manufacture JEM683  IMechE 2006
Micromilling: material microstructure effects 1813

for producing micro-optical components and micro- 2 Jasinevicius, R. G., Campos, G. P. de, Montinari, L.,
tooling inserts could improve their surface finish Tsukamoto, R., Garcia, J. P., Camargo, R., Duduch,
significantly and ultimately lead to significant J. G., and Porto, A. J. V. Influence of the mechanical
improvements in their functional performance. and metallurgical state of an AlMg alloy on the surface
integrity in ultra precision machining. J. Braz. Soc. Mech.
Sci. Engng, JulySeptember 2003, 25(3), 222228.
ACKNOWLEDGEMENTS 3 Duduch, J. G., Porto, A. J. V., Rubio, J. C. C., and
Jasinevicius, R. G. La Influencia del Numero de
The research reported in this paper was funded by Pasadas en la calidad de las Superficies Opticas de
Refleccion. Revista Informacion Tecnologia del Chile,
the UK Engineering and Physical Sciences Research
2000, 11(4), 5358.
Council (EPSRC), the Department of Trade and 4 Rosochowski, A., Presz, W., Olejnik, L., and Richert, M.
Industry (DTI) and the Welsh Assembly Government Micro-extrusion of ultra-fine grain aluminium. In Inter-
(WAG) under the EPSRC Programme The Cardiff national Conference on Multi-material micro manufac-
Innovative Manufacturing Research Centre, the ture (4M 2005) Karlsruhe, Germany, July 2005, pp.
ERDF Programme Micro Tooling Centre, and the 161164.
DTI and WAG MNT Project MicroBridge. Also, this 5 Rosochowski, A., Olejnik, L., and Richert, M. Metal
work was carried out within the framework of the forming technology for producing bulk nanostructured
EC Networks of Excellence Innovative Production metals. J. Steel and Related Mater. Steel GRIPS, Suppl.
Machines and Systems (I*PROMS) and Multi- Metal Forming, 2004, 2, 3544.
Material Micro Manufacture: Technologies and 6 Segal, V. M., Reznikov, V. I., Kopylov, V. I., Pavlik, D. A.,
and Malyshev, V. F. Processy Plasticheskogo Structyr-
Applications (4M). The manufacture of the UFG
oobrazovania Metallov (in Russian). Sci. Engng, Minsk,
material was sponsored by the Scottish Enterprise 1994, 231.
Proof of Concept Fund. 7 Olejnik, L. and Rosochowski, A. Methods of fabricating
The authors would like to thank Professor M. metals for nano-technology. Bull. Polish Academy of
Richert, Faculty of Non-Ferrous Metals, AGH Sciences, Tech. Sci., 2005, 53(4), 413423.
University of Science and Technology, Krakow, 8 Dimov, S., Pham, D. T., Ivanov, A., Popov, K., and
Poland, for providing Figs 2(a) and 3(b) used in this Fansen, K. Micromilling strategies: optimization issues.
study. Proc. Instn Mech. Engrs, Part B: J. Engineering Manufac-
ture, July 2004, 218(B7), 731736.
9 ISO 4288:1996 Geometric Product Specifications
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procedures for the assessment of surface texture, and
1 Popov, K., Dimov, S., Pham, D. T., and Ivanov, A. ISO 11562:1996 Geometric Product Specifications
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