Materials 2013, 6(4), 1434-1451; doi:10.3390/ma6041434
Article

Evaluation of Superficial and Dimensional Quality Features in Metallic Micro-Channels Manufactured by Micro-End-Milling

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Received: 1 March 2013; in revised form: 19 March 2013 / Accepted: 25 March 2013 / Published: 3 April 2013
(This article belongs to the Special Issue Advances in Microelectromechanical Systems (MEMS) Materials)
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
Abstract: Miniaturization encourages the development of new manufacturing processes capable of fabricating features, like micro-channels, in order to use them for different applications, such as in fuel cells, heat exchangers, microfluidic devices and micro-electromechanical systems (MEMS). Many studies have been conducted on heat and fluid transfer in micro-channels, and they appeared significantly deviated from conventional theory, due to measurement errors and fabrication methods. The present research, in order to deal with this opportunity, is focused on a set of experiments in the micro-milling of channels made of aluminum, titanium alloys and stainless steel, varying parameters, such as spindle speed, depth of cut per pass (ap), channel depth (d), feed per tooth (fz) and coolant application. The experimental results were analyzed in terms of dimensional error, channel profile shape deviation from rectangular and surface quality (burr and roughness). The micro-milling process was capable of offering quality features required on the micro-channeled devices. Critical phenomena, like run-out, ploughing, minimum chip thickness and tool wear, were encountered as an explanation for the deviations in shape and for the surface quality of the micro-channels. The application of coolant and a low depth of cut per pass were significant to obtain better superficial quality features and a smaller dimensional error. In conclusion, the integration of superficial and geometrical features on the study of the quality of micro-channeled devices made of different metallic materials contributes to the understanding of the impact of calibrated cutting conditions in MEMS applications.
Keywords: micro-milling; micro-channels; fuel cells; heat exchangers; micro-fluidic devices
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MDPI and ACS Style

Monroy-Vázquez, K.P.; Attanasio, A.; Ceretti, E.; Siller, H.R.; Hendrichs-Troeglen, N.J.; Giardini, C. Evaluation of Superficial and Dimensional Quality Features in Metallic Micro-Channels Manufactured by Micro-End-Milling. Materials 2013, 6, 1434-1451.

AMA Style

Monroy-Vázquez KP, Attanasio A, Ceretti E, Siller HR, Hendrichs-Troeglen NJ, Giardini C. Evaluation of Superficial and Dimensional Quality Features in Metallic Micro-Channels Manufactured by Micro-End-Milling. Materials. 2013; 6(4):1434-1451.

Chicago/Turabian Style

Monroy-Vázquez, Karla P.; Attanasio, Aldo; Ceretti, Elisabetta; Siller, Héctor R.; Hendrichs-Troeglen, Nicolás J.; Giardini, Claudio. 2013. "Evaluation of Superficial and Dimensional Quality Features in Metallic Micro-Channels Manufactured by Micro-End-Milling." Materials 6, no. 4: 1434-1451.

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