Material microstructure effects in micro-endmilling of Cu99.9E

Research output: Contribution to journalArticlepeer-review


  • Ahmed Elkaseer
  • Krastimir Popov
  • L Olejnik
  • A Rosochowski

Colleges, School and Institutes

External organisations

  • Faculty of Computing, Engineering and Science, University of South Wales
  • Institute of Manufacturing Techniques, Warsaw University of Technology
  • University of Strathclyde


This article presents an investigation of the machining response of metallurgically and mechanically modified materials at the micro-scale. Tests were conducted that involved micro-milling slots in coarse-grained Cu99.9E with an average grain size of 30 mm and ultrafine-grained Cu99.9E with an average grain size of 200 nm, produced by equal channel angular pressing. A new method based on atomic force microscope measurements is proposed for assessing materials’ micro-structure effects in micro-machining, that is, the effects of material homogeneity changes on the minimum chip thickness required for a robust micro-cutting processes with a minimum surface roughness. The investigation has shown that by refining the material microstructure the minimum chip thickness can be reduced and a high surface finish can be obtained. Also, it was concluded that material homogeneity improvements lead to a reduction in surface roughness and surface defects in micro-cutting.


Original languageEnglish
Pages (from-to)1-13
Number of pages13
JournalProceedings of the Institution of Mechanical Engineering Part B Journal of Engineering Manufacture
Early online date22 Sep 2016
Publication statusE-pub ahead of print - 22 Sep 2016


  • equal channel angular press- ing, Micro-endmilling, material microstructure, grain size effects, surface finish, surface defects, minimum chip thickness, atomic force microscope