Thin wall geometrical quality improvement in micromilling

Micromilling is one of the most versatile tooling processes being able to effectively manufacture three-dimensional complex features on moulds and dies achieving a good accuracy performance. Typical and challenging features for these microcomponents are high aspect ratio thin walls but no systematic approaches, as the one presented in this paper, exist in literature dealing with the relationship between nominal workpiece characteristics/process parameters, cutting forces, and workpiece quality. The present study focuses on 0.4 % carbon steel (C40) thin wall micromilling and evaluates two approaches for the thin wall geometrical quality improvement: a direct approach (relating process parameters, material and nominal workpiece characteristics to the workpiece quality characteristics) and a force-based approach (relating the same quantities through the cutting forces determination). The force-based approach relates the process parameters to the workpiece quality introducing physical quantities as cutting forces, which are suitable for monitoring and controlling purposes. A suitable experimental campaign has been designed in order to statistically analyze the cutting force responses, and a proper technique (ANalysis of COVAriance) has been applied to remove the tool wear effect. The relationship between cutting forces and workpiece quality has been quantitatively studied; this way, the feasibility of a general approach able to meet tolerances by controlling forces has been demonstrated.