Why Does The Tool Bit Break Easily In Micro Milling?
Micro milling is one of the three common micro cutting techniques used in micro machining.
In micro milling, the tool bit with diameter as small as 0.1mm is held in a high speed spindle rotating at 20,000 to 150,000 rpm, and used to mill steel, brass and aluminum with depth of cut at about 30 microns and feed rates of 120mm/m to 240mm/m to provide surface quality finishes as good as 0.2 microns.
While micro milling has been successfully applied in manufacturing bio-medical components, embossing dies and micro encoders, the breakage of the tool bit has been identified by many users as a teething problem.
Why does the tool bit break so easily in micro milling as compared to conventional milling?
There are 3 main reasons:
Firstly, when metal is removed by machining, there is a substantial increase in the specific energy required as the chip thickness decreases. This means that in the case of micro machining, as the chip gets thinner with smaller depths of cut, the micro tool bit will be subject to greater resistance when compared to conventional machining. It is as if the workpiece...
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