Current trends and future of sequential micro-machining processes on a single machine tool

A sequential micro-machining process chain is described as the machining strategy whereby two or more micro-machining techniques are implemented in sequence on same or different machine tools. This is in contrast to hybrid micro-machining where two standalone machining technologies are integrated together. A recent surge of interest is geared towards building sequential micro-machining capabilities on a single machine tool to avoid realignment and registration errors between processes. One of the major advantages of performing sequential micro-machining on a single machine tool is that it suppresses repositioning errors so enabling much higher levels of accuracy (and thereby tighter tolerances), reduced rejection of machined components, and lower production time; all of these would be otherwise unachievable. Thus, multifunctional micro-machining centres are attracting global interest. Clearly, the necessity of developing reconfigurable, precise and flexible manufacturing is a key driver to this trend. This review aims to provide a critical insight into the recent trends and new classification of sequential micro-machining processes with a special focus on evaluation of such capabilities built on a single machine tool and further potentials. The machining capabilities, advantages and opportunities in the area of sequential micro-machining techniques are evaluated thoroughly and the directions for future work are highlighted.