Micro End Mill Capability Improvement Due to Processing by Fast Argon Atoms and Deposition of Wear-Resistant Coating

Abstract

Micro-milling is widely used to make micro-channels in various fields. In this study, micro-milling of rectangular bronze microchannels was carried out with carbide end mills with a diameter of 1 mm, processed with fast argon atoms, and coated with anti-friction wear-resistant titanium diboride. It was shown that the removal of a 3 µm thick surface layer from a micro end mill with fast argon atoms makes it possible to reduce the cutting edge radius of the tool to 1.2 µm, which is three times lower than the minimum value of 4 µm achievable in mechanical manufacturing. The subsequent deposition of a 3 μm thick anti-friction coating results in a wear-resistant micro end mill with original geometric parameters but improved performance. The surface roughness of the machined bronze microchannel significantly decreased, and the burrs above the groove practically disappeared after micro-milling.