Micro-Milling: Process Modeling and Optimization
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Micro-Milling: Process Modeling and Optimization

Tuğrul Özel

Manufacturing & Automation Research Laboratory

Department of Industrial and Systems Engineering
Rutgers University, New Jersey, USA



Titanium base alloys are widely used as a material of choice in various components in aerospace, chemical, pharmaceutical and medical device industries. In fabricating miniaturize products, the micro-milling process possesses several advantages such as ease of use, process flexibility, low set-up cost, variety in work materials and high material removal rates and is one of the most promising methods for rapid manufacturing of parts with complex three dimensional features in high relative accuracy and precision. However, controlling the micro-end milling process to obtain the desired results is much challenging due to the size effect and some uncontrollable factors. This work presents investigations on integrated physics based modelling and multi-objective optimization approach for micro-milling of Ti-6Al-4V alloy. Micro-milling experiments using various carbide micro-end mills are conducted; surface roughness, burr formation and tool wear are measured. Effects of machining parameters on surface roughness, burr formation, and tool wear are investigated. 2D and 3D Finite element modeling have been utilized to predict forces, temperatures, chip flow and wear rate for micro-tools. Models have been obtained with physics-based and statistically based methods have been also integrated into multi-objective optimization to identify optimum tool path and process parameters. The results indicate that integrated modeling and optimization approach can minimize the average surface roughness and burr formation concurrently.

Bio sketch

Dr. Tuğrul Özel is Associate Professor and Director of Manufacturing and Automation Research Laboratory in the Department of Industrial & Systems Engineering at Rutgers University. He received his Ph.D. from Mechanical Engineering from Ohio State University in 1998. He was a summer faculty fellow at NASA Glenn Research Center in 1999. He teaches courses on manufacturing processes, automation, advanced manufacturing, production systems and simulation modeling. His research program focuses on computational modeling and optimization of manufacturing processes at multi-scale; high speed machining, micro-milling, laser micro-machining, and additive laser sintering processes. Dr. Özel  has published over 100 articles in leading manufacturing journals & conferences, and co-edited two books (Intelligent Machining: Modeling and Optimization of the Machining Processes and Systems, Wiley 2009, and "Micro-Manufacturing: Design and Manufacturing of Micro-Products, Wiley 2011). He is the Founding Editor and Editor-in-Chief of the International Journal of Mechatronics and Manufacturing Systems as well as member on the editorial board of several international journals. He has been member of scientific or program committee on over 25 international conferences. His research has been well funded by National Science Foundation, National Institute of Standards and Technology, NASA and industry. He is senior member of SME, ASME, and Associate Member of the International Academy for Production Engineering, CIRP.