To fully support micro-milling, CAM software should be able to:
â—† Precisely use very detailed mathematical models to maintain their complexity. Having an integrated CAD/CAM solution is ideal because it eliminates any data conversion during processing.
â—† Include high-precision, built-in CAD capabilities within the CAD system to provide styling assistance with appropriate precision and tangential fit within the CAM system (eg, profile capping, extension, etc.).
â—† Support tool path calculation with deviation as low as 0.1 micron. This is especially challenging when machining fine features on large parts.
â—† Support the calculation of micro milling level parameters when considering actual machine constraints.
For example, a CAM system may require a 0.1 mm diameter tool, a 0.005 mm step, and a 10x 0.05 mm tip radius to provide superfine results.
The generated tool path must be accurate to five decimal places
â—† Supports machining strategies optimized for micro-milling, such as roughing, semi-finishing and finishing with the same NC operation.
â—† In order to reduce the machining time while protecting the precision tool from damage, the knowledge of adjusting the feed amount according to the actual machining allowance to control the actual tool load is used throughout the machining process.
Summary: Microsystems, micro-molding and micro-milling are novel and exciting technologies for mass production of micro-parts. With sub-micron precision and tool tips that are almost invisible to the naked eye, this emerging and rapidly growing field presents numerous challenges for moldmakers and suppliers. New materials, new tools, special mold coatings and innovative CAD/CAM software technologies must be researched and mastered.
On the plus side, micro-systems and micro-milling offer new opportunities for moldmakers looking for differentiation, getting more business and being in a better position than low-wage competitors.
Effective development in this area requires cooperation between industry, research institutions and governments. This cooperation is already under way in Europe. The European Union's Technical Cooperation Research Initiative (CRAFT) project brings together Fraunhofer Institute of Production Technology (IPT) and leading suppliers of CAD/CAM, CNC machine tools, tools and fixtures to develop next-generation materials, machine tools and software tools for micro-manufacturing and Working methodology. It is time for the North American tool industry to join the development of this emerging and compelling and profitable market segment.
Introduction to Micro-Milling Micro-system technology has become one of the fastest growing industries in the world, requiring industries that produce extremely small, high-precision parts such as bio-medical equipment, optics, and microelectronics (including mobile communications and computer components). A lot of demand.
Parts requiring micro-system machining have an accuracy of up to 5 mm or less and a surface quality of 0.2 mm or less, and the hardness of parts is also 45 HRC or higher.
Micro-milling is a new processing technology for machining small parts and high-precision parts. Micro-milling uses very small tools (less than 0.1mm in diameter) and can achieve very small surface tolerances and high-quality surface accuracy. Universal NC software cannot achieve this precision, so manufacturers have to face the following huge Challenge: Part deformation, increased complexity, the ability to machine small features with extremely high precision, and the use of special tools in the micron range. For example, a workpiece with a diameter of 0.1 mm meets the above requirements in order to obtain a curved surface with high precision. Micro-milling technology needs to achieve the following support: small-diameter cutters of 100 mm or less; profile ratio (L/D) 10 or up to 100 High speed tool; 150,000r/min or higher spindle speed; 0.1mm or less machining tolerance; ability to correct geometry. Micro-milling is the future of high-speed milling, and companies that are proficient in micro-finishing will be more competitive.
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