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<p>Micro-milling is a key technology&#xa0;in high-tech manufacturing, but improving its reliability and predictability in machining performance remains a major challenge. This comprehensive study examines the entire micro-milling landscape, integrating aspects from fundamental mechanics to practical uses, with a particular emphasis on chip formation. Also, the analysis explores into the complexities of micro-milling and&#xa0;illuminates machining&#xa0;challenges, mechanical fundamentals, machining mechanics, and the development of models for specific workpiece&#xa0;and tool materials. Furthermore, the review emphasizes the complexities of micro-thin wall manufacturing, given the structure&#xa0;sensitivity to dynamic changes, lightweight, and small scale, through a detailed examination of fabrication techniques, deformation analysis, and optimization strategies. The paper concludes with a critical discussion, identifying current limitations and outlining the path for future research, emphasizing the importance of innovations in understanding, monitoring, and refining micro-milling processes for high-precision applications.</p>

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A comprehensive review of micro-milling: fundamental mechanics, challenges, and future prospective

  • 期刊论文

  • 发表日期：

    2025年3月28日

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  • Najeeb Ullah,
  • Muhammad Rehan,
  • Muhammad Umar Farooq,
  • Huaizhong Li,
  • Wai Sze Yip,
  • Sandy Suet To

摘要

Micro-milling is a key technology in high-tech manufacturing, but improving its reliability and predictability in machining performance remains a major challenge. This comprehensive study examines the entire micro-milling landscape, integrating aspects from fundamental mechanics to practical uses, with a particular emphasis on chip formation. Also, the analysis explores into the complexities of micro-milling and illuminates machining challenges, mechanical fundamentals, machining mechanics, and the development of models for specific workpiece and tool materials. Furthermore, the review emphasizes the complexities of micro-thin wall manufacturing, given the structure sensitivity to dynamic changes, lightweight, and small scale, through a detailed examination of fabrication techniques, deformation analysis, and optimization strategies. The paper concludes with a critical discussion, identifying current limitations and outlining the path for future research, emphasizing the importance of innovations in understanding, monitoring, and refining micro-milling processes for high-precision applications.