The characteristics of machined surface controlled by multi tip arrayed tool and high speed spindle

Area of Science:

• Materials Science and Engineering
• Manufacturing Technology

Background:

• Conventional machining struggles with controlling surface roughness and texture in brittle materials due to irregular grinding tool particles.
• Material fragility in conventional methods poses challenges for precise surface finishing.

Purpose of the Study:

• To propose an ultra-precision machining method adaptable to both brittle and soft materials.
• To achieve controlled surface roughness and texture through advanced machining techniques.

Main Methods:

• Utilizing multi-arrayed diamond tips fabricated using Micro-Electro-Mechanical Systems (MEMS) technology for uniform precision.
• Employing a high-speed spindle capable of speeds up to 300,000 rpm.
• Designing specific tool paths and machining patterns for controlled surface modification.

Main Results:

• Demonstrated the ability to machine controlled patterns on surfaces using uniform diamond tips and high-speed rotation.
• Identified key parameters influencing machining outcomes: diamond tip array configuration (n*n), air spindle speed, and feeding rate.
• Successfully controlled surface roughness and texture at the micro-machining level.

Conclusions:

• The proposed ultra-precision machining method offers superior control over surface characteristics compared to conventional techniques.
• The combination of MEMS-fabricated diamond tips and high-speed spindle enables precise surface engineering for diverse materials.
• Optimizing parameters like tip array, spindle speed, and feed rate is crucial for achieving desired micro-machining results.