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Abstract
A new method for fabricating CCMPMPs, namely multi-cutter milling, is proposed and the fabrication principle is discussed. Then, a study of three microchannel parameters, the microchannel depth Hc, width Wc, and interval Ws, and two CCMPMP parameters, the porosity P and the total surface area per unit volume SV, is presented. Furthermore, 3D FEM has been adopted to study the effective stress distribution, the metal flow velocity distribution, and the cutting forces. The results show that CCMPMPs can be successfully machined. Hc, Wc, and Ws can be controlled by the radial depth of cut ae, the slotting cutter thickness Et, and the gasket thickness Eg, while P and SV can be changed by adjusting Hc, Wc, and Ws. Moreover, as ae increases, the average resultant force increases, and the friction between chip and the side face of the machined microchannel, and between chip and the rake face, plays an increasingly important role in it.