Research On Micro Milling Of Grating Structure With Micro Arrayed Slots

Grating structure of micro arrayed slots is composed by many micro slots which are parallel,and characterized by the same width of slot and interval.The service performances of micro parts are directly affected by the dimensional accuracy,burrs,and the machined quality of micro slots.Micro milling is a feasible method to implement high quality machining of micro arrayed slots.However,due to the large number,the small size,and the large length-width ratio of the slots,and the strict requirements for accuracy and consistency,micro end-mills cannot be able to maintain the stiffness and strength.Furthermore,the micro milling process is strongly affected by size effect.To address problems of machining of grating structure with micro arrayed slots,design and fabrication of micro slotting tools and micro milling processes of micro arrayed slots were investigated in this study.The following is a summary of main contents:(1)The micro slotting tools were stemmed from the combination of diamond flying cutting tools and sawing blades.Tool materials,structures and angles were designed according to different requirements.Micro slotting tools with edge width from 0.1mm to 0.4mm were manufactured.(2)Single-factor experiments were performed on copper by single-edged slotting tools with 0.1mm edge width.The effects of milling parameters on dimensional accuracy and burrs were studied.A complete copper grating of micro arrayed slots were manufactured by employing the selected parameters.Tool wear and comparative experiments were performed.(3)Single-factor experiments were performed on pure tungsten by two-edged slotting tools with 0.4mm edge width.The effects of milling parameters on milling forces,surface quality of slot bottom and burrs were studied.Tool wear were also analyzed.Process parameters for micro milling of grating arrays of pure tungsten were collected.(4)Single-factor experiments were performed on titanium alloy by two-edged slotting tools with 0.4mm edge width to find proper ranges of milling parameters.Orthogonal experiments were conducted,and response surface models of surface roughness and burr height were developed.A sample of titanium alloy grating with micro arrayed slots were manufactured.