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IJAT Vol.14 No.2 pp. 245-252
doi: 10.20965/ijat.2020.p0245
(2020)

Paper:

Surface Formation Behaviors in Wavy Microgroove Cutting on Various Workpiece Materials

Toshitaka Terabayashi and Jiwang Yan

Department of Mechanical Engineering, Faculty of Science and Technology, Keio University
3-14-1 Hiyoshi, Kohoku-ku, Yokohama, Kanagawa 223-8522, Japan

Corresponding author

Received:
September 11, 2019
Accepted:
October 9, 2019
Published:
March 5, 2020
Keywords:
wavy groove, micro cutting, roll mold, workpiece material, functional surface
Abstract

Functional films with multi-directional wavy microgrooves can be applied to reduce fluid drag in turbulent flow applications. For high-efficiency mass production of functional films through polymer imprinting, it is necessary to machine wavy microgrooves on the surfaces of metal roll molds. When wavy grooves are cut, to reduce the follow-up errors of machine tools, a very low cutting speed is normally used, but the mechanism of this cutting is still unclear. In this study, microgrooving experiments were conducted on three different workpiece materials: brass, oxygen free copper, and aluminum alloy, and their cutting mechanisms were investigated. Distinct differences in chip formation behavior and machined surface integrity were identified among these materials. Aluminum alloy was chosen as the most suitable material for roll mold fabrication. Two-directional wavy microgrooves with form accuracy on 1 μm level and surface roughness of less than 10 nm Ra were obtained.

Cite this article as:
T. Terabayashi and J. Yan, “Surface Formation Behaviors in Wavy Microgroove Cutting on Various Workpiece Materials,” Int. J. Automation Technol., Vol.14, No.2, pp. 245-252, 2020.
Data files:
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Last updated on Oct. 23, 2020