Generation of micro-textures by three-dimensional vibration-assisted fly cutting

Abstract

Micro-nano textured surfaces exhibit unique functional properties and therefore are extensively applied in the industrial fields such as healthcare and defense. Generally, ultra-precision machining is believed to be an ideal means for fabricating micro-nano textured, especially for vibration-assisted single-point diamond turning. However, vibration-assisted single-point diamond turning also presents challenges in machining micro-grooved or micro-textured surfaces, especially with high curvature properties. Therefore, the present study developed a three-dimensional vibration-assisted fly cutting system to machine micro-texture surfaces. First, a novel three-dimensional vibration platform was designed and utilized to generate the required vibration for modulation the fly cutting tool path, whereby a three-dimensional (X/Y/Z) vibration-assisted fly cutting system is developed by integrating the modified tool offset fly cutting machine tool. Then, by employing the vibration-assisted fly cutting system, sinusoidal excitation signals in the X, Y, and Z directions are generated and combined to create convex bamboo-like micro-textures, concave-convex micro-textures, concave bamboo-like micro-textures, and concave-convex bamboo-like micro-textures. Finally, an analysis of the influencing factors for the generation of concave-convex bamboo-like micro-textures was conducted, and relevant conclusions were drawn. Research results show that by varying the frequency and initial phase of the sinusoidal excitation signals, concave-convex bamboo-like micro-textures with different boundary characteristics were obtained; by adjusting the cutting depth of the tool, concave-convex bamboo-like micro-textures with varying morphologies were achieved. The micro-textured surfaces prepared in this study exhibit excellent surface morphology, proving the effectiveness and reliability of the machining system, which provides valuable insights for the fabrication of micro-textures.