Parameter Optimization of Micromilling Brass Mold Inserts for Microchannels with Taguchi Method

Achieving excellent quality of micromilled surfaces usually requires additional efforts and cost, and Taguchi methodology is an efficient tool in the parameter optimization process. The aim of this study is to explore the optimal cutting parameters for minimal surface roughness of a micromilled brass mold inset, and the controlling parameters included coolant, spindle speed, feed rate, depth of cut, and the stepover. An orthogonal array and factor analysis were carried out to identify the optimal cutting combination, and this combination included air coolant, spindle speed of 45,000 rpm, feed rate of 100 mm/min, stepover of 10% of milling bit diameter, and the depth of cut of 5 mu m To further confirm the analysis, multiple confirmation runs were realized and the averagely measured surface roughness was 0.03 mu m with a stand deviation of 0.004 mu m.