In-process intervention to mitigate built-up edge formation in micro-milling

Abstract

This thesis is focused on developing an in-process intervention technique that mitigates the formation of built-up edges (BUEs) during micro-milling of aluminum. Two different approaches were explored: first, a magnetic field-based process that relies on the use of an abrasive-laden ferromagnetic solution to remove the BUEs attached to the tool, and second, a planetary motion-based three-stage intervention process that uses an abrasive slurry to mechanically remove the BUEs.