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Study on non-isothermal hot-embossing of polymer micro-prism array with efficiency and accuracy
摘要： The isothermal hot-embossing leads to inefficiency because of heating and cooling whole polymer workpiece for precision micro-forming. Hence, a non-isothermal hot-embossing is proposed by compressing and melting a micron-scale surface layer into heated core microgrooves without changing the solid-state workpiece. The objective is to understand how the upper layer micro-prism array is formed on large-size polymer surface with regard to core microgroove parameters and hot-embossing variables. First, the micro-prism shape and sizes were in-process modeled through a hybrid of mechanical compression and hot-melt flowing inside core microgrooves; then the micro-grinding with the trued wheel micro-tip was employed to fabricate various microgrooves on macro-size die cores; finally, the micro-forming accuracy and efficiency were experimentally investigated in hot-embossing. It is shown that the integrated micro-prism array with nanometer-scale surface roughness is rapidly generated inside accurate and smooth core microgrooves with 1-3 seconds. The micro-forming accuracy is dominated by the hot-embossing variables under the limitations of core microgroove parameters. Moreover, the hot-embossed surface roughness reaches 10-30 nm through the hot-melt layer flowing even if the core surface roughness is larger. It is confirmed that the rapid micro-forming sizes and surface roughness may be predicted by the micro-nano core topographies and the hot-embossing variables.
关键词： micro-forming,die core,micro-grinding,hot-embossing,LGP,micro-prism array
更新于2025-09-23 15:21:21
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On-machine texturing of PCD micro-tools for dry micro-slot grinding of BK7 glass
摘要： While using diamond micro-tools for micro-grinding, tool re-clamping errors and low chip removal space from machining zone are the primary factors which cause large vibrations, higher grinding forces and poor surface quality. On-machine tool preparation and tool texturing prior to micro-grinding can reduce tool re-clamping error. It can further help to reduce the tool-workpiece contact area along with enhanced chip removal from the machining zone speci?cally essential during dry micro-grinding as usage of the cutting ?uid should be minimized or completely avoided for environmental aspects. In this study, end faces of polycrystalline diamond (PCD) micro-tools have been on-machine textured using micro electro-discharge machining (micro-EDM) process. Four types of textured tools are envisaged viz. tool with one micro-cavity at the center of the end face (T2), one micro-groove along the end face diameter (T3), two intersecting micro-grooves at the end face (T4) and four intersecting micro-grooves at the end face (T5). A new term “contact area ratio” is de?ned to explain the texture dimension on the end face of the micro-grinding tools. Performances of di?erent micro-textured tools (T2, T3, T4 and T5) with respect to a normal commercial tool (T1) in terms of grinding force, surface roughness and micro-slot quality are investigated for micro-slot grinding of BK7 glass. It is observed that micro-textured micro-grinding tool e?ciently serves the purpose of provisional chip collection in passive grinding areas of the tool whereas chip adhesion or wear on the active grinding areas signi?cantly gets reduced as compared to un-textured tools. Maximum reductions in the x and y direction forces are observed with tool type T5 compared to all other tool types. Reduction in z direction force is comparable for both tool types T2 and T3. Average surface roughness decreased from tool type T1 to type T2, T3 and up to tool type T4 whereas it again increased for tool type T5. The current study shows that textured micro-grinding tools are capable of reducing high normal forces, surface roughness and material dragging which are major concerns during micro-grinding with ?at-end poly-crystalline diamond tools.
关键词： Polycrystalline diamond tool,Micro-texture,Micro-grinding,BK7 glass,Surface roughness,Grinding force,Micro-EDM
更新于2025-09-09 09:28:46