Optimization of corner micro end milling by finite element modelling for machining thin features

Manufacturing thin metal features at miniature scale with high precision milling represents some challenges for different applications such as micro moulds, micro channels, micro gears, surgical instruments, etc. In order to enhance the cutting mechanism understanding and optimize the machining of thin features, 3D finite element modeling (FEM) is applied for the micro end-milling process of thin features. In this study, FE model was used to investigate the minimum wall thickness machinable in order to optimize the experimental machining and enhance the quality of the machined features. Wall thickness uniformity and burr formation were evaluated to achieve the finest overall feature quality. Finally, the FEM prediction results were compared against the experimental tests.