Machined channel quality and tool life using cermet micro-mill in micro-milling aluminum alloy

Based on the superiority of self-developed cermet micro-mill over commercial cemented tungsten micro-mill in our previous work, the cutting characteristics, machined channel quality, and tool wear were investigated in this work, aiming at the evaluation of tool performance of this cermet micro-mill during micro-milling aluminum alloy 2024. Burrs and dimensional accuracy of machined channels, tool wear, and chip morphology were analyzed at various cutting parameters. The machining and forming mechanism related with cermet micro-mill were thoroughly discussed. It indicated that the cutting conditions can be optimized to enhance the performance of cermet micro-mills. The optimum cutting parameter can produce not only the good quality and high dimensional accuracy of channel with few small burrs but also the tool wear to a small degree ever after micro-milling of 10-20min. The cermet micro-mill also exhibited the good capacity to break the chip. The good performance of cermet micro-mill was attributed to its good chemical stability and high hardness, especially the gained sharper tool tips and edges, and their better stability.