Abstract
The demand of ultra-precision micro-machine tools is growing day by day due to exigent requirements of miniaturized components. High accuracy, good dimensional precision and smooth surface finish are the major characteristics of these ultra-precision machine tools. High-speed machining has been adopted to increase the productivity using high-speed spindles. However, machine tool vibration is a major issue in high-speed machining. Vibration significantly deteriorates the quality of micro-machining in terms of dimensional precision and surface finish. This article describes a design methodology of a closed type machine structure for vibration minimization of a high-speed micro-milling center. The rigid machine structure has provided high stiffness and the damping capability to the machine tool without utilizing vibration absorbers. The models of the machine structures have been generated and assembled in AutoCAD 3D. The performance of the integrated micro-milling machine tools was determined by finite element analysis. The best model has been selected and proposed for manufacturing. Additionally, simulation results were validated by comparing with experimental results. Eventually, after manufacturing and assembly, experiments have been performed and it was observed that the amplitude of vibration was approaching towards nanometer level throughout the working range of the high-speed spindle. The machine tool was capable to fabricate miniaturized components with smooth surface finish.
Highlights
Micro-machining technologies have versatile applications in several industries like electro-optics, automotive, biotechnology, aerospace, information technology etc to fabricate high accuracy miniaturized components
The mechanism of chip formation and the grade of surface finish have made high-speed micromilling a distinctive one from other traditional material removal processes [7]
The current study reveals the development strategy of a gantry type machine structure for a high-speed micro-milling center to minimize the machine tool vibration
Summary
Micro-machining technologies have versatile applications in several industries like electro-optics, automotive, biotechnology, aerospace, information technology etc to fabricate high accuracy miniaturized components. The growing demand of micro-machining technology has facilitated the requirement of highperformance and efficient ultra-precision machines tools [1]. Precise complex 3D shapes with mirror finish on different materials can be fabricated in those ultra-precision machine tools in a expeditious and cost-effective way [2, 3]. Micro-milling is an adaptable technology for generating miniaturized components with complex geometric features and mirror finish on difficult-tomachine materials [4, 5], even on silicon [6]. The major limitation of the micro machining is low tool stiffness and low MRR. High speed micro-machining has been adopted to improve MRR and reduce the chip load. The mechanism of chip formation and the grade of surface finish have made high-speed micromilling a distinctive one from other traditional material removal processes [7]
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