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2010-11-03
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A Study of Surface Roughness in Micro-end-milling of Aluminum
Kiha Lee
Sponsored by CODEF and ACLARA
Abstract— A series of experiments has been conducted in order to
characterize the factors that affect surface roughness, and to determine
the range of attainable surface roughness values for the micro-end-
milling process. A 229mm diameter end mill was used to cut slots into
aluminium 6061 samples. The machining factors studied were chip load
(feed per tooth), cutting speed, and depth of cut.
Keywords: aluminum, micro end milling, surface roughness.
1. Introduction
The end-milling process is one of the most widely used material removal processes in
industry. In recent years, the micro-end-milling process has received increased
attention. Micro-end-milling refers to a basic end milling process were tools down to
50 mm in diameter are used. Micro-end-milling is essentially the same process as end-
milling on the macro scale. However, there are a few important differences. As the tool
diameter becomes smaller, the rotational speed theoretically required to achieve the
recommended cutting speed is far above the technical limit of the available spindles.
Another concern in micro-milling is that run-out can become comparable to the
diameter of the tools used. The run-out to tool diameter ratio is much larger for micro-
end-milling than for traditional milling.
2. Experimental setup
A Mori Seiki CNC drilling center was used for the experiments. The drilling center has
a maximum spindle speed of 8000 rpm. However, by using an Air Turbine tool
attachment, operation at 40000 rpm is allowed. A 229 mm diameter tool from
Robbjack Corporation was used for the experiments. The end-mills are made of 92%
WC and 8% Co. Surface roughness measurements were taken with a diamond stylus
(Tenco P-10), traveling along a straight line over the surface of the machined
workpiece. It features the ability to measure micro-roughness with up to 0.5 Å
resolution.
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