Testing procedure for evaluating the performance of a micro-milling process

Several industrial fields show a growing interest in producing components with tiny features realized through micro-cutting processes. Micro-cutting processes cannot be considered as simple downscaling of the conventional process since some phenomena, neglected in macro scale, become predominant in micro scale. Nowadays, in micro-cutting field, guidelines suitable for performing standardized machining tests able to evaluate the performance of a micro-cutting process considering the influence of machine-tool, tool holder, tool, workpiece material microstructure, workpiece fixtures and process parameters are not available. The aim of this paper is to propose a testing procedure for micro-milling process defining the set up to be used and the output to be considered. The suggested procedure was applied using an ultra-precision micro milling machine-tool. This machine was characterized through experimental modal analysis for identify its natural frequencies. The test results show the suitability of the proposed guidelines in evaluating the performance of machine-tool and process when micro-milling features are realized.