Metals Processing

In the column to the right you will find useful information about the processing of metals.

Below you will find recent posts on the 4M Association which are considered to be of interest to the Metals Interest Group.

Diamond Drilling

For special applications diamond turning and milling processes applying monocrystalline diamond tools may not be useful due to their geometric and kinematic limitations. Therefore, diamond contour boring has been developed for the manufactured of micro structured optical molds [A_1].

[A_1] Metal cutting in microstructures, E. Brinksmeier, O. Riemer, Multi-material Micro Manufacture, W. Menz & S. Dimov, 4M2005, pp. 19 - 25.


Technology suitable for both serial and small quantity production

Microdrilling is characterized not just by small drills but also a method for precise rotation of the microdrill and a special drilling cycle. In addition, the walls of a microdrilled hole are among the smoothest surfaces produced by conventional processes. This is largely due to the special drilling cycle called a peck cycle. The smallest microdrills are of the spade type. The drills do not have helical flutes as do conventional drills and this makes chip removal from the hole more difficult.

Fly Cutting

Technology suitable for both serial and small quantity production

Fly cutting is basically a method for cutting grooves. When multiple grooves are cut in different directions, the remaining part can form microconvex shapes such as rectangular columns. Compared to pin making by turning, this method is advantageous in that thin products are not influenced by the machining force, because the machining force is mainly exerted on the rigid base material and not directly on the microcolumn. Fly cutting is particularly useful for producing a large number of microcolumn arrays.


Technology suitable for both serial and small quantity production

Microturning is a method for producing micropins, but it is more difficult to realize other applications. The reason for this is the deformation of the workpiece. This is similar to the case of the microendmilling, however the workpiece in micro turning is often more elastic than the tool in micro­endmilling. Diameters larger than 100 µm is the practically applicable range in case of microturning. It is possible to fabricate another kind of microparts using conventional ultraprecision turning.

Diamond Milling

In diamond milling mainly two different types of processes for the generation of microstructures can be found, i.e. circumferential milling, so called fly-cutting, and ball-end milling. Before micro structuring, the relative position of workpiece and diamond tool have to be known inside the machine tool with respect to each other.

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Metals Processing

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