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<p>Micro-milling has emerged as a critical manufacturing technology for producing complex miniaturized components with high precision and surface quality. Over the past two decades, significant progress has been made in understanding burr formation, tool wear mechanisms, and machinability of advanced materials such as titanium alloys, aluminum composites, and superhard materials. A total of 58 peer-reviewed studies have been cited in the manuscript. We have included recent and relevant literature, including references published in 2025, highlighting developments in tool coatings, lubrication strategies, finite element modeling, and surface integrity analysis. Special attention is given to burr prevention techniques, tool wear control, and the application of cryogenic and minimum quantity lubrication (MQL) methods. Furthermore, recent advances in micro-milling of biomedical polymers and emerging trends in nanocoatings and cutting fluids are discussed. The review also identifies gaps in current knowledge and proposes future research directions, particularly in hybrid machining methods, advanced monitoring systems, and sustainable manufacturing.</p> Graphical abstract <p></p>

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Advances in Micro-Milling and Burr Formation: A Comprehensive Review of Materials, Coatings, and Process Optimization

  • 期刊论文

  • 发表日期：

    2026年4月29日

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  • Ashok Kumar Mishra,
  • Thakur Abhinav Amar

摘要

Micro-milling has emerged as a critical manufacturing technology for producing complex miniaturized components with high precision and surface quality. Over the past two decades, significant progress has been made in understanding burr formation, tool wear mechanisms, and machinability of advanced materials such as titanium alloys, aluminum composites, and superhard materials. A total of 58 peer-reviewed studies have been cited in the manuscript. We have included recent and relevant literature, including references published in 2025, highlighting developments in tool coatings, lubrication strategies, finite element modeling, and surface integrity analysis. Special attention is given to burr prevention techniques, tool wear control, and the application of cryogenic and minimum quantity lubrication (MQL) methods. Furthermore, recent advances in micro-milling of biomedical polymers and emerging trends in nanocoatings and cutting fluids are discussed. The review also identifies gaps in current knowledge and proposes future research directions, particularly in hybrid machining methods, advanced monitoring systems, and sustainable manufacturing.

Graphical abstract