Surface quality and tool wear in micro-milling of single-crystal aluminum

Micro-milling technology is used to machine micro-components and features widely with high surface precision and processing efficiency. To identify the determinants of surface quality of single-crystal aluminum, the micro-milling mechanism of single-crystal materials was characterized based on the shear theory and the mathematical model. The slip plane (111) is the easiest to slip through analysis, so its plastic tendency is the best. A double-edged cemented micro-milling tool with diameter of 0.4 mm was used, and a response surface methodology experiment was conducted on the micro-milling of single-crystal aluminum. By the analysis of variance and range, the factors that impact surface quality were determined as feed rate, spindle speed, and milling depth. A single-crystal surface roughness prediction model was established, allowing the discussion of the influence rules of cutting parameters on the micro-milling surface and analysis of the mechanism and form of tool wear by scanning electron microscopy. These data provide the theoretical and experimental basis for the micro-milling of single-crystal materials.