Creation of Ultraprecision V-shaped Microgrooves Using Non-Rotational Cutting Tools

Abstract

The study deals with the creation of ultraprecision microgrooves using non-rotational diamond cutting tools with angle of 90 degrees, which are mounted on an ultraprecision machining center. Machining experiments of micro grooves were conducted to find the optimal value of cutting speed, depth of cut, rake angle, changing the cutting speed from 1mm/min to 200mm/min, the depth of cut from 0.1m to 10m and the rake angle from -5 degrees to 30 degrees. Workpieces were machined with the cutting tool submerged in the cutting fluid to know the influence of cutting fluid supply method. From the experimental results, the adequate cutting condition is obtained such as the rake angle of 10 degrees to 20 degrees, the finish cutting speed of 1mm/min and the depth of cut in rough cut and finish cut of 1m and 0.5m respectively. As the cutting fluid supply method, workpiece submerged in the cutting fluid is effective. Using the cutting condition, fine V-shaped microgrooves are obtained in various materials. In addition, frontlight optical plate and micro Fresnel lens with the designed micro grooves were designed and manufactured by non-rotational diamond cutting method. As a result, it is also found that the non-rotational diamond cutting method enables to accurately and neatly manufacture microgrooves without any burr generation.