Machining Performance of Microcutting Tools Fabricated by Pulsed Electrochemical Machining (PECM)

Product miniaturization has become increasingly important in modern manufacturing, driven by market demands for compact devices with enhanced functionality. Micromilling has become a pivotal micromachining technology due to its capability to fabricate complex three-dimensional structures with high dimensional accuracy and material removal efficiency. Microcutting tools are an integral part of the micromilling process. Their functional performance is critically dependent on the microgeometry, condition and integrity of the cutting edges, which directly influence chip formation mechanism, surface quality, burr generation, and tool wear. Given the micro sizes and brittle nature of these tools, their manufacturing process is a key factor influencing overall machining performance and cost. To enhance tool quality, reduce production time, and achieve smoother surfaces and cutting edges, the potential of Pulsed Electrochemical Machining (PECM) was investigated in previous study by fabricating two-flute micro end mills made of tool steel with cutting diameters around 1 mm, achieving defined cutting edge geometries with minor and major cutting edge radii of 2.62 ± 0.23 µm and 3.92 ± 1.30 µm, respectively. The current study investigates the machining performance of the microcutting tools fabricated by the PECM process. To evaluate machining performance, the PECM-fabricated microtools were tested by micromilling experiments on aluminium alloy 7075-T6. A comparative analysis was conducted against commercially available microtools of comparable size manufactured by grinding process. Key performance indicators, including cutting forces, tool wear, machined surface quality and burr formation were evaluated.