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New solutions for improving reliability and

reducing uncertainty in micro-milling

Conference Paper · January 2008

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 New solutions for improving reliability and reducing
uncertainty in micro-milling
K. Popov∗, S. Dimov, D. T. Pham and A. Ivanov
Manufacturing Engineering Centre, Cardiff University,
Queens Building, Cardiff, CF24 3AA, Wales, UK

Abstract: To advance micro milling technology it is necessary to study systematically

the factors affecting process reliability, and develop new solutions for reducing
uncertainty when machining components incorporating micro features. This paper
reviews the main findings of the MEC’s research in this field. In particular, the factors
affecting the dynamic stability of the micro milling process and the quality and surface
finish of machined micro components are examined, and solutions are proposed to
broaden its application. These include: new machining strategies that overcome some of
the problems associated with the use of conventional ones for micro milling, such as the
unpredictable life of micro cutters and their premature failure; new methods for tool
failure detection; the use of metallurgical and mechanically modified materials for
improving the process accuracy and resulting surface integrity; new methods for setting
up machine working coordinate systems.
Keywords: micro-milling, machining strategies, tool condition monitoring, CAM

1. INTRODUCTION

Recent developments in machining technology and machine tool design, in particular

micro-milling reflect the constantly increasing requirements towards the accuracy of the
produced components. At the same time, there is a growing trend for product
miniaturisation that leads to continuous reduction of component feature sizes and
correspondingly the diameter of the cutters employed in their machining. In particular,
the applications that ”push” the micro-milling technology to its limits are the
manufacture of micro parts for watches, keyhole surgery, housings for micro-engines,
tooling inserts for micro injection moulding and hot embossing, and housings and
packaging solutions for micro-optical and micro fluidics devices. A common challenge
across all these application areas is the machining of micro features with dimensions
smaller than 100 µm.
There is an increasing demand to make existing products smaller, producing micro
components with tolerances in the submicron range. This is particularly significant in
the medical and electronic industries as well as in sensing and monitoring devices for

Corresponding author: Manufacturing Engineering Centre, Cardiff University, Queens Building, Cardiff,
CF24 3AA, Wales, UK, scekbp@cf.ac.uk
automotive, aerospace and manufacturing industries. Micro-milling is a promising
technology to fulfil today’s those demands on the production of mechanical components
with features in the micrometer range. Its great advantages make micro-milling
especially suitable for micro- manufacturing complex 3D geometries. In particular, it is
applicable on a broad range of materials, accurate in the machining of complex features
and economical for small and medium sizes features. However, challenges like higher
spindle speed, increased positioning accuracy, tool run-out and rigidity, higher removal
rates, burr removal, etc. need to be addressed in order to achieve the desired
competitiveness and increase the current market share [M Madou, 2001], [J. Fleischer et
al., 2006].
In this context this paper reviews the main findings of Cardiff University MEC’s
research in the field of micro milling technology and manufacturing a real micro
component. In this paper, an attempt is made to review the main findings of Cardiff
University MEC’s research and present some solutions for:
• Developing micro-milling technologies by increasing the knowledge related to
micromachining process parameters for different materials.
• Improving micro tools rigidity choosing the proper milling strategy in order to
achieve reliable results. This includes development of specific CAD/CAM modules for
micro-milling processes with optimized milling strategies, tights machining tolerances
and remaining “micro stocks” recognition.
• The unpredictable micro tool life and premature tool failure control by creation of an
innovative Tool Control Monitoring System capable of detecting tool failures as well as
detecting whether or not the tool is machining.
• Developing specific models for micro-milling considering factors like minimum chip
thickness, heterogeneity of the material, ploughing and elastic recovery and grain size of
different materials.

2. PARAMETERS AFFECTING THE PROCESS CAPABILITIES

At first glance, Micro Milling Operations looks like Conventional ones with only
dimensional differences [Altintas Y, et al.]. In practice in most of micro-milling-
operations feed per tooth to tool radius (ft/R) ratio is selected much bigger than
conventional milling in order to keep the productivity. On the other hand stresses on the
tiny micro-tool are much higher than that on a “conventional” tool [J. Chae, et al].
Conventional milling Micro milling
α α
Rake angle Rake angle

TOOL
TOOL R
ft
ft

Workpiece Workpiece

d=20 mm;R~14µm; ft=0.13 mm; ft/R=9 d =0.25 mm;R~2.2µm; ft=2.2 mm; ft/R = 1
 Figure 1; Feed/Radius of cutting edge comparison macro-micro milling
Figure 2 shows the scope of study of the main factors affecting micro milling process
reliability.
Category Parameters
Tool geometry RAKE ANGLE, Lip Relief Angle, Cutting edge radius
Material properties MATERIAL MICRO STRUCTURE, Strength, Ductility,
Strain-Hardening Coefficient, Temperature Dependence
Process conditions FEED, CUTTING SPEED, Use of Coolant
CAD/CAM New micro-Milling “strategies”-GENERATING TOOL PATH
considering some limitations
Others Tool Diameter, Tool wear, Tool material, Machine Stiffness

SAME Tool Geometry and Work Material

Feed, Cutting Speed Process Reliability

Tool Wear Cutting Edge Radius

Figure 2; Parameters affecting micro milling process reliability
These conditions have a significant impact on tool life that can be less than one hundred
inches of tool path length when hard metals are machined. Thus, the selection of
optimal machining strategies and parameters, and the use of appropriate monitoring
techniques are key factors affecting the process reliability [Liu Kai, 2005]. In particular,
to machine features at “micro” scale successfully the following two issues are
significant:
• The machining strategy should be selected by taking into account the specific
geometry of the component. This includes the selection of a cutting depth that keeps
milling forces within predefined limits along the machining path.
• The spindle speed and the feed rates should be chosen depending on the workpiece
and the cutting tool materials.
To develop machining strategies that are designed specially for micro-milling the
following issues should be taken into account:
• It is very important to avoid sharp corners at rib-web junctions. At such corners
fillets should be introduced to reduce the stress concentration and thus prevent part
failures.
• Sharp changes in the direction of the cutting forces should be avoided when
machining microstructures with thin features. Especially, this is the case when ball nose
cutters are employed [Dimov S, et al., 2004].
• The axial component of the cutting forces should be kept within predefined limits
otherwise it could excite the workpiece and cause vibrations.
• Special measures should be taken to avoid cutting tool breakages because small
cutters are extremely vulnerable to varying process conditions.
While the tool corner radii are necessary to produce fillets, e.g. between ribs and webs,
the use of ball-nose cutters only in machining microstructures reduces the material
removal rates because the cusp should be minimised [C. R. Friedrich and M. J. Vasile].
To achieve higher removal rates and vibration-free machining it is a good practice to
carry out micro-milling operations in two steps. First, milling with the biggest possible
diameter cutter with a zero corner radius and just leaving sufficient material to form the
fillets. Then, the remaining material is removed using a ball-nose cutter to produce
smooth surfaces. To avoid the cusp, prevent chatter, and limit the occurrence of
vibrations during micro-milling the step over distance and spindle speed should be
calculated following special guidelines for performing cutting at such a scale [K Popov,
et al., 2006, p.1677]. In addition, other process parameters affect directly or indirectly
the accuracy and surface quality of the machined features. These include side steps, step
over movements, the depth of cut, feed-rates per tooth, cutting speeds, cutting tool wear,
and the use of cutting fluid/air/oil mist. The effects of these factors on the micro-milling
process are investigated and discussed in [Dimov S, et al., 2004; K Popov, et al., 2006,
p.1677]. They should be taken into account in developing micro-machining strategies.

3. NEW “MICRO”-MACHINING STRATEGIES

The strategy selected to carry out the machining of feature(s) in a part determines the
series of machining sequences that will be employed to complete the job successfully. It
defines the methodology that will be used for planning cutter-paths and generating
optimal sequences of machining operations for each particular job. Thus, the selected
strategy determines the cutter and the machining algorithm that will be applied, the
removal area/volume, and the corresponding technological parameters [Altan et all,
2001]. It also determines the machining parameters associated with the selected cutters
and removal volumes. In particular, the feed-rates, the spindle speeds, the depth of cut
(step-down), the width of cut (step-over), and the ramp angle for plunge cutting should
be specified.
To carry out micro-milling successful the selected machining strategy should remove
material via very shallow cuts with a step-over parameter of around one-third of the
cutter diameter. In order to maintain constant cutting conditions during the machining,
the goal should be to remove constant volumes of material during machining and thus
ensure constant tool load and contact between the cutter and the workpiece [Dimov S.,
et al., 2004].
Two approaches for roughing and finishing may generally be applied:
• The first approach is used mainly when the cutting conditions for roughing and
finishing differ significantly. In this case, the roughing and the finishing must be carried
out with different machining sequences. The vertical walls of the pockets should be
machined by applying Z-level profile cutting with climb milling. Due to the high cutting
speeds, the cutters should be engaged in the machining through a gentle ramping and
when the tool path contains sharp corners, quick turns should be minimized.
• In the second approach the roughing passes are followed immediately by finishing
passes as part of one machining sequence. This approach is more appropriate for micro-
milling. In this case, the tool paths that are usually used for roughing are Z-level cutting
patterns with a helical engagement. Very good results were obtained when the finishing
passes were performed by applying the follow contour method. This is a universal
strategy that can be utilized for machining ‘hard’ and ‘soft’ wall pockets especially
when very thin walls have to be machined.
Taking all these into account new micro-milling strategies were proposed [Dimov S, et
al., 2004]. In particular, a new method for removing sharp corners during roughing
passes was implemented in which the material was removed in Z-level steps, while
maintaining constant chip load through successive inner boundary contour offsets. In
this way the variations in cutting conditions were minimised in order to extend the tool
life. For machining typical features in micro parts a set of Expert Machinist templates
were developed in Pro/ENGINEER. The advantages and disadvantages of using
different machining strategies for micro-milling were studied and then their capabilities
were verified experimentally. By employing the latest advances in CAM technology it
was possible to tune existing machining strategies to the specific requirements of micro-
milling operations.
Follow up research focussed on optimising these new machining strategies for milling
thin features [K Popov, et al., 2006, p.1677]. For example, employing these strategies it
was possible to machine thin ribs with wall thickness down to 20 µm as it is shown in
Figure 3.

Figure 3; The machined thin ribs: (a) Quick Vision picture; (b) a surface mapping
profile of the ribs
The conclusions made from this research were:
• The tool path should be selected in such a way that the ribs and webs being machined
are supported by specially designed fixtures or un-machined areas of the workpiece.
Moreover, the cutting should proceed from the least supported area toward the best
supported thin features in a component.
• For thin webs, it is important to minimise the force component normal to the web.
This means that most of the machining has to be performed using a tool with no corner
radius.
• In case fillets between ribs and webs are required, they should be machined initially
in a number of subsequent passes by removing the material layer by layer. Then, the
resulting small steps are removed in a follow-up milling operation using a cutter with
the required corner radius. The machining of these steps should be carried out with
spindle speeds that are sufficiently low to prevent any vibration occurring.

4. TOOL CONDITION MONITORING

Unpredictable tool life and premature tool failure are major problems in micro-
machining [T. Matsumura; D. Spath and K.H. Sternemann; H.K. Tonshoff et all, 1988].
Unfortunately, the operators of micro-milling machines cannot detect the breakage of
the cutters visually due to their small diameters, and the generated chips and cooling
mist in the machining area. Also, the acoustic “footprint” of the micro-milling process is
such that it is not possible to distinguish its acoustic emissions from those generated by
the machine. Thus, the only solution is the use of Tool Condition Monitoring Systems
(TCMS) to improve the effectiveness of micro-milling operations.
Three new systems for detecting tool breakage during micro-milling and drilling were
designed and implemented into prototype TCMS’s [Gandarias, E. et al.]. The operating
principles of these systems are as follows:
• Reflective single-beam laser system - Its main components are a reflective laser
sensor and an amplifier for processing the data. The sensor is fixed on the machine head
by attaching it to the machine spindle using a clocking arm. Tool conditions are
monitored by focusing a laser beam with a spot size of 50 µm constantly on the cutter,
and at the same time, directing the beam reflection towards a receiver as shown in
Figure 4.

Figure 4; The reflective single-beam laser system

• To avoid “hidden” areas, for example when milling pockets or grooves, the laser
beam is focused just above the tool working length. Then, the light intensity of the
reflected beam is measured using the amplifier to detect indirectly any tool breakages.
The advantages of this method are that it could detect tool breakages instantly and that
such systems could be applied in the machining of any conductive or non-conductive
material.
• Tool-workpiece voltage monitoring system (TWVMS) - Figure 5 depicts the general
principles of this system. By creating a close electrical circuit between the spindle and
the workpiece, abrupt voltage variations during the cutting process can be detected with
a specially designed sensor. This sensor allows the alternating voltage to be measured
without being in direct contact with the spindle rotating parts. For further processing,
the measurements taken are converted into a digital signal and are sent to the CNC
controller. It should be noted that since this method monitors variations in the voltage
during the machining, it is applicable only when machining conductive materials.
+

Z
+2
_
7* Spindle
Sensor
+2
R3 V C1 Tool
+2
R4 Holder
_ +3
To PLC + Tool
R2 C R1
Workpiece

Table

Figure 5; TWVMS -the general principles

• Off-line laser system - This approach requires tool measurement routines to be
carried out “off-line” by employing standard laser systems that are commonly used on
micro-machining centres for automating tool setting up procedures. This is done by
executing a tool breakage detection cycle that checks the tool length. It should be
stressed that during the execution of this routine, the spindle speed is maintained
unchanged and hence so is the spindle temperature. If any tool breakage is detected, an
error message appears on the screen and the NC programme stops. This is a very cost-
effective solution. Its main disadvantages are that the system cannot detect tool failures
between the measuring cycles, and the increase of the machining time because it is an
off-line solution.
Prototype systems were developed to validate the feasibility of these tool failure
detection methods experimentally. By combining their capabilities an integrated
solution can be developed for detecting tool failure during micro milling and drilling.
Such a new tool monitoring system promises to increase significantly the process
productivity, improve the precision and the quality of the machined components, and
ultimately, reduce their manufacturing costs.

5. MATERIAL MICROSTRUCTURE EFFECTS

The typical cutting conditions in micro milling imply that the material removal process
is governed by the interfacial interaction between the cutter and the workpiece material.
Because of this, the microstructure of the workpiece can play a fundamental role in the
cutting process [Duduch, J.G et al., 2000], [A. Rosochowski et al., 2004]. The effects of
material properties on the micro cutting mechanism are considered extremely important.
The milling strategies that were optimised for micro machining thin features [K Popov,
et al., 2006, p.1677] were applied in [K Popov, et al., 2006, p.1807] to investigate the
effects of the workpiece microstructure on part quality and surface integrity. The
machining response of mechanically and metallurgically modified Al alloy when
milling thin features in micro-components was studied. The investigation has shown
that through refinement of a material’s microstructure it is possible to improve
significantly the surface integrity of the machined micro features. In particular, the
following conclusions were made.
• The roughness of micro-features produced by micro-milling was highly dependent
on the material grain size. For example, the surface roughness of thin features in micro-
components improved more than three times as a result of the reduction of the grain
sizes and material anisotropy of the Al alloy used in the experiments from 100-200 µm
to 0.6 µm.
• A “favourable” crystalline texture of the material in regard to the machining
direction and the narrow grain size distribution could lead to surface roughness
improvements. However, such improvements are of a magnitude smaller than those
achievable through a refinement of the material grain structure.
• There is an important correlation between the subtle structural features of the
material and the post process surface quality. The different results obtained after micro-
milling of conventionally processed and Ultra Fine Grained (UFG) metals demonstrated
that the creation of sub-grains on its own could not lead to significant improvements of
surface integrity without reducing the grain size and the material structural anisotropy.
Further research is required to benefit from the grain size effects in manufacturing
micro components in a range of micro-engineering applications. For example, the use of
UFG brass as a material for producing micro-optical components and micro-tooling
inserts could improve significantly their surface finish and ultimately lead to significant
improvements of their functional performance.

6. CONCLUSIONS

This paper reviewed the main findings of Cardiff University MEC’s research in micro-
milling technology. The main factors affecting the dynamic stability of the micro
milling process and the quality and surface finish of machined micro components were
examined and compared with macro scale cutting [J. Tlusty, P. Macneil, 1975].
The general principles that should be followed in designing machining strategies for
such features are developed, tested, and guidelines given for their correct
implementation. Following these principles, new strategies are proposed to reduce the
negative effects of identified factors on part quality, and at the same time to overcome
some of the main problems in micro milling of “critical” thin features.
The implementation of the appropriate strategies in conjunction with the evaluated
parameters cutting speed (Vc) and feed per tooth (ft) allows better final surface
roughness of the micro milled features to be achieved.
The experimental results show that:
• The resulting surface roughness is linearly proportional to ft;
• Surface roughness is proportional to tool wear;
 • Proper ft could be found for longer tool life (decrease tool wear);
• For micro milling (ft/R < 1) tool life increases as Vc increased. Unfortunately
there is a machine tool and spindle limitation.
Tool failure detection research has demonstrated the feasibility of three different
indirect methods for detecting tool breakage during micro-milling and drilling.
Prototype systems developed and then verified give a basis to compare their capabilities.
An important advantage of all the proposed tool failure detection methods is that they
do not introduce any restrictions on cutting tool movements.
The implementation of developed tool monitoring system increases significantly the
process productivity, improve the precision and the quality of the machined components,
and, ultimately, reduce their manufacturing costs.
The mechanisms of surface improvement by refining the grain structure of metal alloys
and the changes in the machining response were investigated. The results of the research
carried out and reported demonstrate clearly that there is an important correlation
between the isotropy/homogeneity of the material and the post process surface quality.
The different performance of the CP and ECAP samples shows that a grain refinement
on its own cannot lead to significant improvements of surface integrity without
reduction of material structural anisotropy.

ACKNOWLEDGMENTS

The research reported in this paper is funded under the MicroBridge programme
supported by the Welsh Assembly Government and the UK Department of Trade and
Industry, the EPSRC Programme “The Cardiff Innovative Manufacturing Research
Centre”. Also, it was undertaken within the framework of the EC Networks of
Excellence “Multi-Material Micro Manufacture: Technologies and Applications (4M)”.

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