Modeling and optimization of micro scale pocket milling operations
Author(s)
Advisor
Karpat, YiğitDate
2014Publisher
Bilkent University
Language
English
Type
ThesisItem Usage Stats
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Abstract
Manufacturing of micro scale parts and components made from materials having
complex three dimensional surfaces are used in today’s high value added products.
These components are commonly used in biomedical and consumer electronics
industries and for such applications, fabrication of micro parts at a low cost without
sacrificing quality is a challenge. Micro mechanical milling is a viable technique which
can be used to produce micro parts, however the existing knowledge base on micro
milling is limited compared to macro scale machining operations.
The subject of this thesis is micro scale pocket milling operations used in micro mold
making which are used in micro plastic injection in mass production polymer micro
parts. Modeling of pocket milling while machining of basic pocket shapes are
considered first. The developed milling model is then extended to more complex mold
shapes. Minimum total production time is used as the objective to solve single pass,
multi pass, and multi tool problems. Case studies are presented for each problem type
considering the practical issues in micro milling. A software has been developed to optimize machining parameters and it is shown that the developed pocket milling
optimization model can successfully be used in process planning studies.