Abstract
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.
Highlights
Due to superior features like color dispersion [1], super-hydrophobicity [2] and corrosion inhibition [3], the hierarchical surface is widely applied in optics, energy, electronics, etc. [4]
The above technologies still take a great deal of time to determinate complicated toolpath, which must meet the requirements of fabricating the primary surface and the secondary structures at the same time
A dual-axial tool servo diamond turning is developed in this paper for fabricating hierarchical micro-nano-structured surfaces
Summary
Due to superior features like color dispersion [1], super-hydrophobicity [2] and corrosion inhibition [3], the hierarchical surface is widely applied in optics, energy, electronics, etc. [4]. The developments of toolpath determination [14] and error compensation [15] further improve the machining precision of the primary surface On this basis, fly cutting has been able to fabricate the pyramid secondary structures via removing materials from different directions. For most cutting technologies of fabricating the primary surface, exerting the assisted vibration can naturally induce periodic residual tool mark on the machined surface, namely the secondary structure. The ultra-precision diamond turning can be modulated into the process like milling for fabricating the micro/nano channels with different bottom surface [27]. A dual-axial tool servo diamond turning method for ductile materials is proposed to develop the vibration-assisted machining through applying additional vibration along the direction that is perpendicular to the cutting depth direction.
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