A review on high speed micro-milling of shape memory alloy (NiTinol): process and post perspective

High-speed micro milling of NiTinol shape memory alloy, a material with unique properties such as superelasticity and shape memory effects, has emerged as a promising technology for precision manufacturing in industries like aerospace and biomedical devices. This review paper comprehensively explores the process and post- process aspects of machining NiTinol using high-speed micro milling. The paper delves into critical parameters, tooling strategies, and machining optimization techniques specific to NiTinol, highlighting the challenges associated with its machinability. The selection of cutting tool materials, including Tungsten Carbide, Coated Carbides, Ceramics, Cubic Boron Nitride, and Polycrystalline Diamond, is discussed in detail. Post-process considerations, such as inspection methods, surface quality assessment, and dimensional accuracy evaluation, are explored to ensure the quality and integrity of machined NiTinol components. Sustainability and environmental impact are also considered, with an emphasis on energy efficiency, material waste reduction, minimum quantity lubrication, and tool material selection. The review concludes by identifying key future research directions, including advanced monitoring techniques, novel tool materials, optimization of machining strategies, environmental sustainability, surface finish enhancement, integrated process-post-process analysis, and tailored applications for the aerospace and biomedical sectors. Notably, sustainability aspects of high-speed micro milling offer energy efficiency gains and material waste reduction potentials. The paper concludes by highlighting the transformative potential of high-speed micro milling in revolutionizing manufacturing capabilities and fostering innovation across various industries.