Deformation control in micro-milling of thin-walled structures

Deformation and fracture are primary problems encountered in the machining of thin-walled structures, especially when micro-milling is employed. To resolve these problems, we propose a novel method that was developed by theoretical analysis and experimental investigation. The mechanical properties of micro-milling were analysed, and it was found that the axial force acting on the thin wall of a machined U-shaped structure significantly contributed to the deformation and fracture of the structure. A low-melting point alloy (LMPA) was therefore used as an auxiliary support to balance the axial force exerted by the micro-milling cutter, thereby enhancing the rigidity of the thin-walled workpiece. To evaluate the performance of the proposed method, a 15-μm-thick beryllium bronze alloy was machined by precision micro-end-milling tools. The results confirmed the effectiveness and feasibility of the method for deformation control during the micro-milling of thin-walled components.