Fabrication of hierarchical micro-groove structures by vibration assisted end fly cutting

Abstract

Bionic linear micro-groove structure is a common structure in nature, with special functions such as self-cleaning and structural color. Although fast tool servo assisted diamond turning is believed to be an effective method for machining micro-structures, it suffers from defects such as insufficient dynamic response frequency and tool interference in machining linear micro-groove structure. In the present study, a novel vibration-assisted tool end fly cutting technique is proposed to achieve linear micro-groove structure and the hieratical micro-structure surface by the crossing of micro-grooves. A uniform circular tool path is generated by the tool end fly cutting to perform the principal cutting, while a two-degree-of-freedom servo-vibration platform provides high-frequency, low-amplitude and multi-modal actuation compatible with the principal cutting motion. Then the tool path required for the composite machining of the micro-groove structure surface is planned, and a uniform and consistent micro-groove structure surface can be generated. The machining capability of the system is verified the experimental machining of multi-layer micro-groove structures. This study provides a technology reference for the preparation of micro-groove structure surfaces.