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A new tool holder design with two-dimensional motion for fabricating micro-dimple and groove patterns

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International Journal of Precision Engineering and Manufacturing Aims and scope Submit manuscript

Abstract

This paper presents an elliptical vibration machining (EVM) method, which is utilized to establish a micro-dimple or groove pattern for surface texturing. The EVM has been explored extensively by the precision community to significantly improve machining performance through lower cutting force, reducing tool wear, burr suppression, extended tool life and lower surface roughness. A new design of a tool holder has been developed, yielding two-directional motions of the tool tip of about 10 μm and 30 μm in the axial and transverse directions, respectively. The tool holder design uses a four-bar flexure hinge, of which the flexure body has a first natural frequency of about 4.6 kHz according to an impact test. In this research, two piezo actuators have been driven in open-loop conditions by energizing two sinusoidal voltages from a function generator with the developed tool holder attached to a conventional computer numerical controlled (CNC) 3-axis milling machine. The micro-dimples and grooves have been successfully built using a vibration frequency of 100 Hz with various phases between 15o and 60o to verify the cutting performance of the developed tool holder.

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Abbreviations

K R :

Overall stiffness of the flexure body

K B :

Bending stiffness of single circular flexure hinge

K S :

Linear stiffness of single circular flexure hinge

F :

Generated force from piezo actuator

x, z :

Cartesian coordinate axis

D 1 , D 2 :

Output displacement of 1st and 2nd piezo actuators

L 1 , L 2 :

Length of the center rotation perpendicular to force direction in the z and x directions

A 1 , A 2 :

Amplitude of sinusoidal waves

f m :

Frequency vibration

t :

Time

φ :

Phase shift

ϕ :

Half of angle between first and second piezo

θ :

Half of angle between link B1 and B2

C L (X T , Z T ):

Cutter location point

F T :

Texturing feed

F G :

Grooving feed

Δ d :

Distance between tip tool and a surface

DOC :

Depth of cut

α :

Rake angle

β :

Clearance angle

R :

Radius of cutting tool insert

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Authors and Affiliations

  1. School of Mechanical Engineering, Yeungnam University, 214-1, Dae-dong, Gyeongsan-si, Gyeongsanbuk-do, South Korea, 712-749

    Rendi Kurniawan & Tae Jo Ko

Authors
  1. Rendi Kurniawan
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  2. Tae Jo Ko
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Correspondence to Tae Jo Ko.

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Kurniawan, R., Ko, T.J. A new tool holder design with two-dimensional motion for fabricating micro-dimple and groove patterns. Int. J. Precis. Eng. Manuf. 15, 1165–1171 (2014). https://doi.org/10.1007/s12541-014-0452-4

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  • DOI: https://doi.org/10.1007/s12541-014-0452-4

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