scholarly journals Micro Milling Process for the Rapid Prototyping of Microfluidic Devices

2021 ◽  
Author(s):  
Muhammad Syafiq Rahim ◽  
Abang Annuar Ehsan
Keyword(s):  
Rapid Prototyping ◽  
Cross Section ◽  
Rectangular Cross Section ◽  
Microfluidic Devices ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Hydrodynamic Focusing ◽  
Manufacturing Method ◽  
Microflow Cytometer

Micro milling process has become an attractive method for the rapid prototyping of micro devices. The process is based on subtractive manufacturing method in which materials from a sample are removed selectively. A comprehensive review on the fabrication of circular and rectangular cross-section channels of microfluidic devices using micro milling process is provided this review work. Process and machining parameters such as micro-tools selection, spindle speed, depth of cut, feed rate and strategy for process optimization will be reviewed. A case study on the rapid fabrication of a rectangular cross section channel of a microflow cytometer device with 200 um channel width and 50 um channel depth using CNC micro milling process is provided. The experimental work has produced a low surface roughness micro channel of 20 nm in roughness and demonstrated a microflow cytometer device that can produce hydrodynamic focusing with a focusing width of about 60 um.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

scholarly journals Numerical Analysis of Laser Heating for Laser Assisted Micro Milling Application

2013 ◽  
Vol 465-466 ◽  
pp. 720-724 ◽  
Author(s):  
Zazuli Mohid ◽  
N. M. Warap ◽  
S. Hassan ◽  
M.I.S. Ismail ◽  
R. Ibrahim ◽  
...  
Keyword(s):  
Laser Beam ◽  
Milling Process ◽  
Micro Milling ◽  
Life Extension ◽  
Depth Of Cut ◽  
Beam Irradiation ◽  
Melted Zone ◽  
Temperature Distributions ◽  
Laser Beam Irradiation ◽  
Processing Techniques

The promising processing techniques of micro scale parts are very important in products miniaturization and functions enhancement. Combination of two or more processing techniques gives better processing performance especially when dealing with difficult-to-cut materials. For that reason, the combination of laser beam and micro milling process has been widely studied and proven efficient in reducing cutting force and tool life extension. However, this process needs a precise temperature control in order to eliminate heat effect generated by laser beam irradiation. In this study, temperature distributions are determined numerically to characterize the melted zone and heat affected zone geometry. From the results, the estimation of tool and micro milling cutter distance together with the allowable depth of cut are determined.

Experimental Study of Micro-Milling Microchannels on Polycarbonate Substrates

2014 ◽  
Vol 974 ◽  
pp. 132-135 ◽  
Author(s):  
Pin Chuan Chen ◽  
Chang Wei Pan
Keyword(s):  
Factor Analysis ◽  
Feed Rate ◽  
Lower Cost ◽  
Microfluidic Devices ◽  
Spindle Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Application Fields ◽  
Polycarbonate Substrate

How to fabricate a disposable microfluidic device is a growing interest in many application fields and micromilling is one of the efficient approaches. The benefits of using micromilling for polymer microfluidic devices include shorter fabrication process, lower cost, easier user interface, and being capable of fabricating complicated structures. The aim of this study is to use factor analysis to determine the optimal cutting conditions in micromilling microchannels on polycarbonate substrates. The parameters included spindle speed, feed rate, and the depth of cut, and the micromilled roughness was measured by a stylus profilemeter. The smallest roughness achieved was 0.127μm with the spindle speed of 20,000rpm, feed rate of 300mm/min, and the depth of cut of 10μm. From factor analysis results, the spindle speed has the largest influence while the depth of cut has the minimized impact to the surface quality of a micromilled polycarbonate substrate.

Investigation on Cutting Forces and Surface Finish in Mechanical Micro Milling of Zr-Based Bulk Metallic Glass

2019 ◽  
Vol 18 (01) ◽  
pp. 113-132
Author(s):  
Debajyoti Ray ◽  
Asit Baran Puri ◽  
Nagahanumaiah
Keyword(s):  
Surface Roughness ◽  
Metallic Glass ◽  
Cutting Force ◽  
Bulk Metallic Glass ◽  
Cutting Parameters ◽  
Milling Process ◽  
Spindle Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Axial Depth

Precision micro-component fabrication demands suitable manufacturing processes that ensure making of parts with good form and finish. Mechanical micro milling represents a flexible and powerful process that exhibits enhanced capability to create micro features. Bulk metallic glass (BMG) represents a young class of amorphous alloy material with superior mechanical and physical properties and finds appreciable micro scale applications like biomedical devices and implants, micro parts for sport items and various other micro- components. In the present work, an attempt has been made to analyze the influence of the cutting parameters like spindle speed, feed per tooth and axial depth of cut on the machinability of BMG, in mechanical micro-milling process. The micro-milling process performances have been evaluated concerning to cutting forces and surface roughness generated, by making full slots on the workpiece with solid carbide end mill cutters. The paper presents micro-machining results for bulk metallic glass machined with commercial micro-milling tool at low cutting velocity regime. Response surface methodology (RSM) has been employed for process modeling and subsequent analysis to study the influence of the combination of cutting parameters on responses within the selected domain of cutting parameters. It has been found that the effect of axial depth of cut on the cutting force components is remarkably significant. Cutting force components increases with the increase in axial depth of cut and decreases with increase in spindle speed. At low feed rate, cutting force in the feed direction (Fx, i.e., cutting force along x-direction) increases with a decrease in feed rate. This increase of force could be due to the possible ploughing effect. A similar pattern of variation has been observed with cutting force component in cross-feed direction (Fy) also. It has been found that effect of feed per tooth on the roughness parameter Ra is remarkably significant. Surface roughness increases with feed per tooth. Axial depth of cut does not contribute much to the surface roughness. Surface roughness decrease with the increase of spindle speed.

Machining Parameters Mapping’s of Inconel 718 and Aluminum Alloy 1100 in Micro-Milling Process

2020 ◽  
Vol 846 ◽  
pp. 99-104
Author(s):  
Gandjar Kiswanto ◽  
Maulana Azmi ◽  
Adrian Mandala ◽  
Dede Lia Zariatin ◽  
Tae Jo Ko
Keyword(s):  
Aluminum Alloy ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Machining Parameters ◽  
Workpiece Material

The development of micro-products in industry, like aviation, medical equipment, electronics, etc, has been increasing lately. The need for scaling down of product has been increasing to make the product simpler and complex. Micro-milling has capabilities in producing complex parts. In this study, mapping and comparing the result of the machining process of Inconel 718 and Aluminum Alloy 1100 was employed. In this experiment, Inconel 718 was used as workpiece material and the result of Aluminum Alloy taken from recent studies. Then, A cutting tool with a diameter 1 mm carbide coating TiAlN was used in this experiment. The machining process was performed with three varieties of spindle speed and feed rate with a constant depth of cut. After the machining is done, the mapping of the result surface roughness of Inconel 718 and AA1100 performed. It was found that Inconel 718 has poor machinability compared with AA 1100. Inconel 718 also has a high manufacturing cost compared to AA 1100 because the cutting tool was easy to wear.

Cutting Parameters Impacting on Tool Wear in Micro End-milling of Tool Steel

2018 ◽  
Author(s):  
Cínthia Soares Manso ◽  
Cleiton Lazaro Fazolo de Assis ◽  
Luciana Wasnievski da Silva de Luca Ramos ◽  
Erik Gustavo Del Conte
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Diameter

In micro milling process, the quick wear and premature breakage of tools configure a problem that affects not only the process costs but also the manufacturing quality. This work investigates the influence of the cutting parameters on tool wear and surface roughness in a dry machining of a tool steel H13 workpiece (X40CrMoV5-1). Spindle speed was kept constant (27200 rpm) and two feeds per tooth were applied (1.5 and 3.0 µm) as depth of cut (25 and 30 µm), and variating cut length as well. The wear of the tool top area, tool diameter and nose radius were monitored during micro milling tests. Roughness was evaluated by using a Laser Confocal Microscope. The lower level of feed per tooth and depth of cut showed lower roughness, but a higher tool wear. A balance between cutting parameters and cutting length must be considered to ensure micromachining without severe tool wear and preserve microchannel features along its machined surface.

Experimental Study on Milling Hardened SKD Steel Using Micro CBN Ball-End Mills

2010 ◽  
Vol 126-128 ◽  
pp. 773-778
Author(s):  
Yung Tien Liu ◽  
Neng Hsin Chiu ◽  
Yen Chun Lin ◽  
Chih Liang Lai ◽  
Yu Fu Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Machined Surface ◽  
Performance Function ◽  
End Mills

Micro ball-end milling process features the ability of machining complex surfaces, precision machining accuracy, and excellent machined surface roughness. However, because the diameter of a micro milling tool is very small, a rapid progress of tool wear or even tool breakage usually happens when machining a high-strength hardened mold steel using improper machining parameters. As a result, the machining cost would rise due to the quality defect in machined workpiece. In this study, to investigate how the machining parameters affect the cutting behaviors, a series of experiments using micro CBN ball-end mills with a diameter of 0.5 mm were performed to cut the SKD11 mold steel with hardness of HRC 61. The machining parameters are selected as the feeding speed (f) being 840, 960 and 1,080 mm/min, depth of cut (ap) being 30, 45, 60 μm, and spindle speed (vs) being fixed as 30,000 rpm. According to the experimental results, the measured three-axis cutting forces, flank wears, and surface roughness of machined workpiece are highly related to the cutting length. It is expected that the measured results can be used to construct a performance function of a micro ball-end tool. With referring to the performance function, the tool life can be well expected, and thus a progress in machining efficiency without tool failure can be achieved.

Micro Milling for Polymer Materials Used in Prototyping of Microfluidic Chip Application

2012 ◽  
Vol 565 ◽  
pp. 552-557 ◽  
Author(s):  
Aramcharoen Ampara ◽  
Kah Chuan Sean Shaw ◽  
Kui Liu
Keyword(s):  
Aspect Ratio ◽  
Microfluidic Chip ◽  
Microfluidic Devices ◽  
Milling Process ◽  
Polymer Materials ◽  
Micro Milling ◽  
Machined Surface ◽  
Biocompatible Polymer ◽  
Machined Surface Quality ◽  
Materials Used

Micro milling is one of the processes that can be used in microfluidic devices fabrication. It has shown the capability for producing the freeform geometries, cost and time effectively. This paper presents the cutting strategies for micro milling process for an application of microfluidic device. The proposed strategies demonstrated the capability of micro milling process to fabricate microchannel and micropillar array from biocompatible polymer materials with good machined surface quality and high aspect ratio of up to three.

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