Study on Surface Roughness in Micro Milling of Single Crystal Materials

Micro milling is a machining method of high precision and efficiency for micro components and features. In order to study the surface quality of single crystal materials in micro milling, the two-edged cemented carbide tool milling cutter with 0.4 mm diameter was used, and the orthogonal experiment was completed on the micro-milling of single crystal aluminum material. Through the analysis of statistical results, the primary and secondary factor which impacting on surface quality were found as follows: spindle speed, feed rate, milling depth. The ideal combination of optimized process parameters were obtained, when the spindle speed was 36000 r/min, the milling depth was 10 μm, the feed rate was 80 μm/s, which made the milling surface roughness is 0.782 μm and minimal. Single crystal materials removal mechanism were revealed, and the influence of cutting parameters on micro-milling surface were discussed, the reason of tool wear was analyzed. Those provide a certain theoretical and experimental basis for micro milling of single crystal materials.