Offset-tool-servo diamond end flycutting multi-layer hierarchical microstructures

Zhang, Guoqing; Ma, Shuang; Wang, Jianpeng; Jiang, Jiankai; Luo, Tong; Wang, Haitao

doi:10.1016/j.ijmecsci.2022.107645

Cited by 10 publications

(3 citation statements)

References 58 publications

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“…Fly cutting and single-point diamond turning, as an ultra-precision machining technique, has been widely used for fabricating micro structure arrays [187,193,194]. For MAAs, Zhang et al [195] fabricated a macro lens array using an offsettool-servo diamond end fly cutting process (figure 14(a)). Figure 14(b) shows the simulated and machined morphologies of the macro lens array, and the results indicated that the macro lens units were uniformly aligned into a lens array.…”

Section: Micro-mechanical Cutting Machiningmentioning

confidence: 99%

Recent progress in bio-inspired macrostructure array materials with special wettability—from surface engineering to functional applications

Lian,

Zhou,

Ren

et al. 2023

Int. J. Extrem. Manuf.

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Bio-inspired macrostructure array (MAA, size: submillimeter to millimeter scale) materials with special wettability (MAAMs-SW) have attracted considerable attention due to their outstanding performance in many fields, such as oil repellency, liquid/droplet manipulation, anti-icing, heat transfer, water collection, and oil−water separation. In this review, we mainly focus on recent developments in the theory, design, fabrication, and application of bio-inspired MAAMs-SW. First, we briefly introduce the basic theory of special wettability. Afterwards, we discuss representative structures and corresponding functions of some biological surfaces. Then, we summarize fabrication methods of special wetting MAAs from the three categories of additive manufacturing, subtractive manufacturing, and formative manufacturing, including 3D printing, laser etching, wire electrical discharge machining, micro-mechanical cutting machining, electrochemical machining, template method, and imprinting method. In addition, we demonstrate the applications of these MAAMs-SW. Lastly, the challenges and directions of future research on bio-inspired MAAMs-SW are briefly addressed.

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Section: Micro-mechanical Cutting Machiningmentioning

confidence: 99%

Recent progress in bio-inspired macrostructure array materials with special wettability—from surface engineering to functional applications

Lian,

Zhou,

Ren

et al. 2023

Int. J. Extrem. Manuf.

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show abstract

“…However, the tool diameter limits the achievable structure size by micromilling [39]. Fly cutting can ensure surface quality uniformity and provide flexibility for machining hierarchical microstructures [40], but it is challenging to generate high-aspect-ratio microstructures. Grinding is fit for fabricating microstructures like micropillars and grooves on difficult-to-cut materials [41].…”

Section: Introductionmentioning

confidence: 99%

Elliptical vibration chiseling: a novel process for texturing ultra-high-aspect-ratio microstructures on the metallic surface

Li,

Zhang,

Zheng

et al. 2024

Int. J. Extrem. Manuf.

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High-aspect-ratio metallic surface microstructures are increasingly demanded in breakthrough applications, such as high-performance heat transfer enhancement and surface plasmon devices. However, the fast and cost-effective fabrication of high-aspect-ratio microstructures on metallic surfaces remains challenging for existing techniques. This study proposes a novel cutting-based process, namely elliptical vibration chiseling (EV-chiseling), for the high-efficiency texturing of surface microstructures with an ultrahigh aspect ratio. Unlike conventional cutting, EV-chiseling superimposes a microscale elliptical vibration on a backward-moving tool. The tool chisels into the material in each vibration cycle to generate an upright chip with a high aspect ratio through material deformation. Thanks to the tool’s backward movement, the chip is left on the material surface to form a microstructure rather than falling off. Since one microstructure is generated in one vibration cycle, the process can be highly efficient using ultrafast (>1 kHz) tool vibration. A finite element analysis model is established to explore the process mechanics of EV-chiseling. Next, a mechanistic model of the microstructured surface generation is developed to describe the microstructures’ aspect ratio dependency on the process parameters. Then, surface texturing tests are performed on copper to verify the efficacy of EV-chiseling. Uniformed micro ribs with a spacing of 1~10 μm and an aspect ratio of 2~5 have been successfully textured on copper. Compared with the conventional EV-cutting that uses a forward-moving tool, EV-chiseling can improve the aspect ratio of textured microstructure by up to 40 times. The experimental results also verify the accuracy of the developed surface generation model of microstructures. Finally, the effects of elliptical trajectory, depth of cut (DoC), tool shape, and tool edge radius on the surface generation of micro ribs have been discussed.

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“…Diamond tool flycutting, a form of ultra-precision cutting, removes surface material intermittently and is particularly suited for machining microstructures of straight-groovetype such as pyramid microstructure arrays [27]. Zhu et al [28] achieved the preparation of a micro-pyramid array with ultra-precision flycutting on the C-axis mode.…”

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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Offset-tool-servo diamond end flycutting multi-layer hierarchical microstructures

Cited by 10 publications

References 58 publications

Recent progress in bio-inspired macrostructure array materials with special wettability—from surface engineering to functional applications

Recent progress in bio-inspired macrostructure array materials with special wettability—from surface engineering to functional applications

Elliptical vibration chiseling: a novel process for texturing ultra-high-aspect-ratio microstructures on the metallic surface

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

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