Conventional cutting fluids as coolants and lubricants are being widely used in various machining processes, but these cutting fluids give rise to biological and environmental problems. The advantages of implanting micro texture on macroscopic cutting tools have been proved widely in implementing sustainable machining. But seldom studies focused on preparing micro texture on the surface of micro end mill with diameter less than 1 mm. In this study, an attempt has been made to create curvilinear grooved micro textures on the rear surface of double helical micro end mills with diameter of about 800 μm by electrical discharge machining (EDM) method for lowering specific milling energy and forces. Then, dry micro milling experiments were performed on aluminum alloy material using micro end mills with or without curvilinear grooved micro textures. The surface generated mechanism, force time- varying characteristics, specific milling energy, chip capacity and tool wear form of curvilinear grooved micro end mills in dry micro milling are revealed. Besides, the effects of structural parameters of micro textures and process parameters on specific milling energy and dry micro milling forces are discussed. Experimental results disclosed that the average specific cutting energy involved in dry micro milling process of aluminum alloy material machined by micro end mill with curvilinear grooved micro textures is decreased by 21.35%. The normal and tangential forces are significantly reduced compared to ordinary micro end mill. The voids and stomatal located in micro textures fabricated by EDM method are found to be conductive to store and accommodate some extrusion chips. For micro end mill with curvilinear grooved micro textures, the oxidative wear is more serious but the adhesion wear is slighter than ordinary micro end mill. This research is expected to prepare and optimize micro textured micro end mills suitable for dry micro milling process, which has important theoretical significance and engineering application value.

传统的切削液作为冷却剂和润滑剂被广泛用于各种加工过程，但这些切削液会引起生物和环境问题。在宏观切削刀具上植入微观纹理的优势已在实施可持续加工中得到广泛证明。但很少有研究关注在直径小于1mm的微型立铣刀表面制备微织构。在这项研究中，已尝试通过放电加工 (EDM) 方法在直径约 800 μm 的双螺旋微型立铣刀的后表面创建曲线凹槽微纹理，以降低特定的铣削能量和力。然后，使用带有或不带有曲线凹槽微织构的微型立铣刀对铝合金材料进行干式微铣削实验。揭示了干式微铣削中曲线槽微立铣刀的表面生成机制、力时变特性、比铣削能量、切屑容量和刀具磨损形式。此外，讨论了微织构的结构参数和工艺参数对比铣削能量和干微铣削力的影响。实验结果表明，采用微立铣刀加工具有曲线凹槽微织构的铝合金材料，干式微铣削加工平均比切削功降低了21.35%。与普通微型立铣刀相比，法向力和切向力显着降低。发现通过 EDM 方法制造的微纹理中的空隙和气孔具有导电性，可以存储和容纳一些挤压碎片。对于具有曲线凹槽微织构的微型立铣刀，氧化磨损更严重，但粘附磨损比普通微型立铣刀轻。本研究有望制备和优化适用于干式微铣削工艺的微织构微立铣刀，具有重要的理论意义和工程应用价值。