![]() ![]() Two chip loads: Top one has chip thickness > tool edge radius. To understand why that is, consider our diagram that shows how rubbing occurs when chip load gets too low relative to the radius of the cutting edge: What kinds of changes happen at these scales?įor example, the geometry at these scales is such that the rake on the cutters is almost always negative. That’s larger than a lot of folks expect, and it’s larger than we normally think of as micromachining. Big Kaiser suggests these changes in cutting physics start to set in with tool diameters of 0.100″ or less. The feeds and speeds formulas and calculations that work reasonably well for larger cutters need quite a bit of adjustment for smaller cutters to account for these changing conditions. Micro-endmills live in a different world than most of our cutters are used to. It’s a Different World at Micromachining Scales – Semiconductor and Electronics, where miniaturization and even nanoscale technologies become the norm.Īll these and many more applications require the use of micromachining techniques. – Medical Components, which often require tiny screws and other devices. – Fiber Optics, which involve precise use of lasers and focusing of light to very tight tolerances. These waveguides are often micromachined. – Microwaves, where the frequencies are so high that signals travel in tiny waveguides rather than through wires. – Microfluidics, where tiny channels for the fluids are machined. There are many applications for micromachining such as: What sorts of things require this tiny work? Consider these tiny Turner’s Cubes, for example: Some of the work done with micromachining is truly beautiful and spectacular. The world of micromachining is all about either very small features on normal-sized parts, or very tiny parts. Cutters smaller than 1/8″ or about 3mm are used for micromachining. Given that we typically want accuracies that are about 1/10 of the tolerances required, micro-machining requires accuracies in the 0.0001″ or less range. Either way, these are very small numbers. A little more common definition says it involves cutters smaller than 0.015″ in diameter and tolerances measured in tenths. Makino says micro-milling involves features smaller than about 0.001″ ( what they actually say is smaller than 0.00098″). Micro-mills look similar but operate in a different world than conventional cutters do… Click here to learn more about the Master Class. Note: Micromachining is Lesson 16 of our Free Email Feeds & Speeds Master Class.
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