Study of micro channel fabrications by micromilling

In order to bridge the gap between high quality micro channel fabrications and micromilling processes, experimental studies have been conducted. First, single-factor experimental study has been conducted to identify the reasonable ranges of key process parameters considering the size effect in microcutting. Second, Taguchi method has been applied to conduct orthogonal experiments for the optimisation of micromilling process parameters. It shows that the importance order in sequence on the surface roughness is the axial depth of cut ap, the feed fz, and the radial depth of cut ae. Then, the regression equation has been introduced to predict the surface roughness according to the key process parameters. Third, three up/down micromilling modes together with two kinds of cutter entry positions have been experimentally studied. It shows the microfluidic channel is better to be micromilled by the commensurate sized micro end mills and the open-end microchannel design is preferred.