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2 2025

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Comprehensive review of tool treatments and innovations in micro-milling precision and performance

Rathod Vipul Prabhakar, Wankhade Sandeep Haribhau

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 4

241--257

Advancements in micro milling, tool treatments, and ultra-precision machining centers have significantly enhanced the fabrication of micro-scale components across various industries. This paper provides a comprehensive review of recent developments in these areas, focusing on the impact of tool material innovations, surface treatments, and state-of-the-art machining centers on machining accuracy, surface finish, and tool longevity. The integration of advanced tool treatments and ultra-precision machining technologies has led to improved performance and expanded applications in fields such as biomedical engineering, electronics, and aerospace. The study discusses need and advantages of tool coating, and cryogenic treatment on tools for efficient machining and enhancement of tool life. Future research directions are also discussed, emphasizing the need for continued innovation to meet the growing demand for high-precision micro-manufacturing.

A review on impact of micro-tools on micro-milling outcomes for aluminium alloy

Rathod Vipul Prabhakar, Wankhade Sandeep Haribhau

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 3

322--340

Micro milling is a highly precise machining technique that uses high-speed, miniature cutting tools to create intricate geometries, achieve fine tolerances, and deliver excellent surface finishes. This process is especially valuable in industries that work with lightweight aluminum alloys. These materials are not only favored for their low weight but also for their impressive strength-to-weight ratios and resistance to corrosion. However, machining aluminum alloys presents several challenges, including rapid tool wear, material buildup on tool surfaces, and poor heat dissipation. These issues can significantly impact tool life and compromise surface quality. Tungsten carbide tools have become the go-to choice for micro milling due to their hardness, wear resistance, and thermal stability. While untreated tungsten carbide tools are commonly used, they often face limitations such as abrasive wear, thermal cracking, and reduced performance in high-speed machining environments. To address these challenges, researchers have explored solutions like applying thin-film coatings and surface treatments to improve wear resistance, reduce friction, and extend tool life. More recently, cryogenic treatment has gained attention as a promising method to enhance the mechanical properties of tungsten carbide tools. This process can refine the material’s structure and improve its thermal conductivity, potentially making the tools more durable and efficient. This review will bring together and critically evaluate existing studies that focus on the performance of untreated, coated, and cryogenically treated tungsten carbide tools during micro milling of aluminum alloys. By comparing the results of different tool treatments, the review aims to provide insights into optimizing tool configurations to enhance machining efficiency and extend tool life.