Novel tool offset fly cutting straight-groove-type micro structure arrays

Jiang, Jiankai; Luo, Tong; Zhang, Guoqing; Dai, Yuqi

doi:10.1016/j.jmatprotec.2020.116900

Cited by 24 publications

(7 citation statements)

References 14 publications

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“…The micro-structure array is shown in Figure 12 [55]. Luo et al studied the wear process of metal-bonded diamond grinding wheel in the process of sapphire single crystal surface grinding to find the mechanism of the influence of grinding wheel wear on workpiece surface quality [128]. Polishing is usually one of the last processes of UPM, which can eliminate the surface and sub-surface damage of the machined parts and improve the surface shape.…”

Section: Liga Technologymentioning

confidence: 99%

See 1 more Smart Citation

A Review of Advances in Fabrication Methods and Assistive Technologies of Micro-Structured Surfaces

Zhang

Cao

et al. 2023

Processes

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Micro-structured surfaces possess excellent properties of friction, lubrication, drag reduction, antibacterial, and self-cleaning, which have been widely applied in optical, medical, national defense, aerospace fields, etc. Therefore, it is requisite to study the fabrication methods of micro-structures to improve the accuracy and enhance the performance of micro-structures. At present, there are plenty of studies focusing on the preparation of micro-structures; therefore, systematic review of the technologies and developing trend on the fabrication of micro-structures are needed. In present review, the fabrication methods of various micro-structures are compared and summarized. Specially, the characteristics and applications of ultra-precision machining (UPM) technology in the fabrication of micro-structures are mainly discussed. Additionally, the assistive technologies applied into UPM, such as fast tool servo (FTS) technology and slow tool servo (STS) technology to fabricate micro-structures with different characteristics are summarized. Finally, the principal characteristics and applications of fly cutting technology in manufacturing special micro-structures are presented. From the review, it is found that by combining different machining methods to prepare the base layer surface first and then fabricate the sublayer surface, the advantages of different machining technologies can be greatly exerted, which is of great significance for the preparation of multi-layer and multi-scale micro-structures. Furthermore, the combination of ultra-precision fly cutting and FTS/STS possess advantages in realizing complex micro-structures with high aspect ratio and high resolution. However, residual tool marks and material recovery are still the key factors affecting the form accuracy of machined micro-structures. This review provides advances in fabrication methods and assistive technologies of micro-structured surfaces, which serves as the guidance for both fabrication and application of multi-layer and multi-scale micro-structures.

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Section: Liga Technologymentioning

confidence: 99%

“…Table 4. SEM figures of machined structures by fly cutting [54,128,192,193]. [119,177,184,[189][190][191].…”

Section: Micro-structure Materialsmentioning

confidence: 99%

A Review of Advances in Fabrication Methods and Assistive Technologies of Micro-Structured Surfaces

Zhang

Cao

et al. 2023

Processes

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“…Zhu et al [29] proposed a machining technique combining flycutting with slow-tool-servo, namely, endflycutting-servo technology, which generated hierarchical micro/nano structures with pyramid shapes on a four-axis ultra-precision lathe. Jiang et al [30], aiming to reduce machine costs, first proposed a method for fabricating pyramid microstructures based on linearized cutting with an end flycutting on a three-axis (X-, Z-, C-axis) ultra-precision lathe using a reverse interpolation algorithm to simulate Y-axis functionality. The reduction in ultra-precision lathing costs is more advantageous for commodity production.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Polymethyl Methacrylate (PMMA) Hydrophilic Surfaces Using Combined Offset-Tool-Servo Flycutting and Hot Embossing Methods

Wang,

Zhang

et al. 2023

Polymers

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Polymethyl methacrylate (PMMA) is a material with good surface wettability and has unique and widespread applications in industrial fields. However, fabricating this material in an environmentally friendly way while maintaining its mechanical robustness remains a challenging task. One effective way is through the rational design of microstructure surfaces. The current study fabricated a pyramid microstructure array on a mold surface using offset-tool-servo flycutting, which was then combined with hot embossing to replicate an inverted pyramid microstructure array on a PMMA surface. Firstly, a toolpath compensation algorithm was developed to linearize the arc toolpath and reduce the cost of ultra-precision lathe. Then, the algorithm was further developed to achieve automatic linear toolpath intersection, aiming to ensure the machining accuracy and improve machining efficiency. An experiment testing the linear toolpath intersecting at 90° was conducted, fabricating a pyramid microstructure array with nanoscale roughness on the mold surface. This surface was then employed for replicating an inverted pyramid microstructure array on the PMMA surface using hot embossing. Furthermore, the accuracy of replication was evaluated, and the experimental results demonstrated excellent replication fidelity, exceeding 98%. The microstructural surface of the PMMA exhibited a change in surface wettability. The wettability test showed a water-droplet contact angle reduction from 84.8° ± 0.1° to 56.2° ± 0.1°, demonstrating a good hydrophilic effect. This study introduces a novel, environmentally friendly and high-precision method to fabricate a functional PMMA surface with an inverted pyramid microstructure array. The results of this study also provide strong technical support and theoretical guidance for micro-nanostructure functional surface machining and replicating.

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“…On this basis, fly cutting has been able to fabricate the pyramid secondary structures via removing materials from different directions. The designed cross toolpaths form specific residual tool marks, namely the pyramid secondary structures, the topography of which can be adjusted by redesigning the toolpath spacing and the cutting direction [16]. The rotary ultrasonic diamond cutting also has the capacity to fabricate the hierarchical surface.…”

Section: Introductionmentioning

confidence: 99%

Dual-Axial Tool Servo Diamond Turning of Hierarchical Micro-Nano-Structured Surfaces

Zhu

Chen

et al. 2021

JMMP

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This paper reports on a dual-axial tool servo diamond turning method for the one-step fabrication of hierarchical micro-nano-structured surfaces. With respect to the dual-axial servo motion (XZ), the z-axis motion can generate the primary surface with a complex shape, and the x-axis motion is used to synchronously form the secondary structure via controlling the residual tool marks. The toolpath determination algorithm for the developed turning method is described in detail, and the effect of the machining parameters on the basic feature and sizes of the generated secondary structures is investigated through conducting the numerical simulation for both toolpath and surface generation. The simulation result indicates that the additional x-axial motion is effective for the deterministic generation of a variety of secondary structures. Finally, taking advantage of an ultra-precision lathe with a self-developed tri-axial FTS, a hierarchical surface with high accuracy is practically generated.

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Novel tool offset fly cutting straight-groove-type micro structure arrays

Cited by 24 publications

References 14 publications

A Review of Advances in Fabrication Methods and Assistive Technologies of Micro-Structured Surfaces

A Review of Advances in Fabrication Methods and Assistive Technologies of Micro-Structured Surfaces

Fabrication of Polymethyl Methacrylate (PMMA) Hydrophilic Surfaces Using Combined Offset-Tool-Servo Flycutting and Hot Embossing Methods

Dual-Axial Tool Servo Diamond Turning of Hierarchical Micro-Nano-Structured Surfaces

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