Abstract
Polymers with surface microstructure have promising prospects for applications in the domains of aerospace, integrated circuits, and optical engineering. Ultra-precision cutting has unique advantages in the preparation of microstructure with high precision and complex shape. However, the inherent characteristics of polymers such as high elasticity, strong toughness, and poor thermal conductivity bring ultra-precision cutting a great challenge. In this study, the rectangular groove microstructures on polymers were fabricated by ultra-precision diamond cutting, and the influence of matrix material, feedrate and cutting depth on cutting performance and dimensional accuracy was quantitatively evaluated. The results indicate that the polyimide (PI) exhibits a good machinability compared with polyetheretherketone (PEEK) and polytetrafluoroethylene (PTFE). In addition, the feedrate have a negligible influence on the morphologies and dimensional accuracy of groove structure, while the groove width decreases and the ridge width increases as the cutting depth increases from 10 μm to 100 μm. The groove structure has the best dimensional accuracy when the cutting depth is 10 μm. Furthermore, the material removal mechanism of PI was discussed detailedly based on the results of numerical simulation and experiment.
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