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In order to further improve the dimensional accuracy of micromilled thin walls with high aspect ratios, the machining process should be actively controlled. A device for active cutting force measurement and cutting parameter compensation is developed to realize the real-time measurement of radial cutting forces and compensation of radial cutting parameters in thin wall cutting process. Firstly, a mathematical model is established to calculate the deformation and cutting force of thin walls based on the cantilever beam deformation theory. The thin wall deformation in the cutting process is estimated by measuring the cutting force. Then, the obtained incremental thin wall deformation is to be compared with the compensation threshold, which is set at 0.5 μm. If the value of the incremental deformation is less than 0.5 μm, compensation will not be processed. Otherwise, the incremental deformation is used as the compensation value for iterative compensation, until the incremental deformation of the thin wall is less than 0.5 μm. At last, a contrast experiment is carried out. The experimental results show that the introduced device and compensation method are feasible. Machining quality of the thin wall has been obviously improved in dimension precision after the cutting parameter compensations.

Previous studies found that the peripheral cutting edge and end cutting edge in micro end milling had different cutting phenomena considering the size effect in micro cutting processes. This paper is a further study on this point considering different workpiece materials and cutting edge radii. Finite element simulations have been conducted to determine the minimum undeformed chip thickness (MUCT) by the chip morphology and the results are verified by micromilling experiments. Both the simulations and experiments show that the MUCT of the peripheral cutting edge and the end cutting edge are different even if the cutting edge radii remain unchanged. The MUCT is directly proportional to the cutting edge radius. Material properties also have some effects on the MUCT of the peripheral cutting edge. But it has limited effects on that of the end cutting edge. The results indicate that the feed engagement other than the axial depth of cut should be carefully selected in micro end milling when considering different workpiece materials.

In order to improve the machining quality and reduce the dimensional errors of micro high-aspect-ratio straight thin walls, the on-line cutting parameter compensation device has been introduced and corresponding micromilling processes have been investigated. Layered milling strategies for the micromilling of thin walls have been modeled and simulated for thin walls with different thicknesses based on the finite element method. The radial cutting parameters compensation method is adopted to compensate the thin wall deformation by raising the radial cutting parameters since the thin wall deformation make the actual radial cutting parameters smaller than nominal ones. The experimental results show that the dimensional errors of the thin wall have been significantly reduced after the radial cutting parameter compensation. The average relative dimensional error is reduced from 6.9% to 2.0%. Moreover, the fabricated thin walls keep good shape formation. The reduction of the thin wall dimensional error shows that the simulation results are reliable, which has important guiding significance for the improvement of thin wall machining quality, especially the improvement of dimensional accuracy. The experimental results show that the developed device and the machining strategy can effectively improve the micromilling quality of thin walls.

Wire electrochemical micromachining (WECMM) technology is regarded a promising method to fabricate high aspect ratio microstructures on hard-to-machining materials, however, the by-product accumulation in the machining gap limits its application. In this paper, a new method called ultrasonic-assisted wire electrochemical micromachining (UA-WECMM) is proposed to improve the machining performance of WECMM. Firstly, a flow-field simulation in the machining gap was carried out, the results showed that the ultrasonic vibration of electrode can remarkably enhance the mass transport in the machining gap and improve the machining condition. Secondly, experiments were performed to confirm the effect of ultrasonic vibration, which illustrated that the vibration with proper amplitude can reduce the slit width and improve the morphology of machined surface. Moreover, the influence of other machining parameters were also discussed. Finally, a T-type micro connector with good surface roughness (Ra 0.286 &mu, m) was fabricated on a 300-&mu, m-thick 304 stainless steel workpiece and a micro gear (diameter: 3.362 mm, Ra: 0.271 &mu, m) with an aspect ratio of 7 was fabricated on a 2-mm-thick workpiece. It is proved that the proposed ultrasonic-assisted wire electrochemical micromachining method has considerable potential and broad application prospects.

K9 optical glass has superb material properties used for various industrial applications. However, the high hardness and low fracture toughness greatly fluctuate the cutting force generated during the grinding process, which are the main factors affecting machining accuracy and surface integrity. With a view to further understand the grinding mechanism of K9 glass and improve the machining quality, a new arithmetical force model and parameter optimization for grinding the K9 glass are introduced in this study. Originally, the grinding force components and the grinding path were analyzed according to the critical depth of plowing, rubbing, and brittle tear. Thereafter, the arithmetical model of grinding force was established based on the geometrical model of a single abrasive grain, taking into account the random distribution of grinding grains, and this fact was considered when establishing the number of active grains participating in cutting Nd-Tot. It should be noted that the tool diameter changed with machining, therefore this change was taking into account when building the arithmetical force model during processing as well as the variable value of the maximum chip thickness amax accordingly. Besides, the force analysis recommends how to control the processing parameters to achieve high surface and subsurface quality. Finally, the force model was evaluated by comparing theoretical results with experimental ones. The experimental values of surface grinding forces are in good conformity with the predicted results with changes in the grinding parameters, which proves that the mathematical model is reliable.

High-speed mechanical micro drilling would be a promising process for small hole fabrications with high productivity and high quality. But there are limited studies on this topic. Fundamental questions such as the minimum undeformed chip thickness (MUCT) due to the size effect in microcutting, burr size, cutting force, and optimal parameters are discussed for high-speed mechanical micro drilling in this paper. Based on finite element method (FEM) modelling, the MUCT is identified as 0.86 μm for copper C26000 with the cutting edge radius of 5 μm from both chip generation and force variation analyses. The ratio of MUCT to the cutting edge radius is 0.17, which is smaller than that (usually 0.2 or 0.25 for copper) in micro shaping and micromilling processes. This result has been successfully verified by experiments with the drill with a diameter of 1 mm and the spindle speed of 80,000 min-1. Burr width at the hole entrance reaches the maximum value when the undeformed chip thickness (UCT) is smaller than the MUCT. Experimental optimizations with the integrated considerations of cutting forces and burrs have been conducted. The optimal high-speed micro drilling parameters have realized a material removal rate (MRR) of 25% increasement compared with conventional micro drilling.