Machining dynamics and chatters in micro-milling: A critical review on the state-of-the-art and future perspectives

Abstract

Micro-milling technology is widely applied in micro manufacturing, particularly for the fabrication of miniature and micro components. However, the chatters and machining dynamics related issues in micro-milling are often the main challenges restricting its machining quality and productivity. Many research works have rendered that the machining dynamics and chatters in micro-milling are more complex compared with the conventional macro-milling process, likely because of the size effect and rigidity of the micro-milling system including the tooling, workpiece, process variables, materials involved, and the high-speed milling machines, and further their collective dynamic effects. Therefore, in this paper, the state of the art focusing on micro-milling chatters and dynamics related issues over the past years are comprehensively and critically reviewed to provide some insights for potential researchers and practitioners. Firstly, typical applications and the problems caused by the machining dynamics and chatters in micro-milling have been put forward in this paper. Then, the research on the underlying micro-cutting mechanics and dynamics, stability analysis, chatters detection, and chatter suppression are summarized critically. Furthermore, the underlying scientific and technological challenges are discussed particularly against typical precision engineering applications. Finally, the possible future directions and trends in research and development of micro-milling have been discussed.