Rapid Generation of Surface Dimples Using End Milling
Shinichi Kogusu*, Takakazu Ishimatsu**, and Yasuhiko Ougiya**
*Industrial Technology Center of Nagasaki, 2-1303-8, Ikeda, Omura, Nagasaki 856-0026, Japan
**Dept. of Mechanical Systems Eng., Nagasaki University, 1-14 Bunkyo-machi, Nagasaki 852-8521, Japan
Structured surfaces on metal are often employed to enhance lubricating features, reduce the hydrodynamic drag force along wings and also decorate the metal surfaces for architectural ornament. It is important to note that only horizontal movements of a ball-end mill at high feed speed generate the indented surface on metal surfaces. In this paper we propose a technique to estimate the dimples generated on the metal surfaces using a machining center with an oval-end mill. Firstly, a technique to simulate the generating process of the dimples with the machining center is explained. The technique is effective in forecasting the geometry of the dimples with accuracy. Secondly, a technique to determine the cutting condition to generate the desired dimpled surface is proposed. The design specifications of the dimpled surface are the geometry of the dimples and the spacing between the dimples. The proposed technique was successfully used to decorate a metal surface.