Title: Influence of clearance angle on micro/nano structure fabrication in elliptical vibration cutting of hardened steel

Authors: Jianguo Zhang; Norikazu Suzuki; Yilong Wang; Eiji Shamoto

Addresses: Engineering Research Center of Extreme Precision Optics, State Key Laboratory of Applied Optics, Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Science, Changchun, China ' Department of Mechanical Science and Engineering, Nagoya University, Nagoya, Japan ' Makino Milling Machine Co., Ltd., Kanagawa, Japan ' Department of Mechanical Science and Engineering, Nagoya University, Nagoya, Japan

Abstract: Surfaces textured by sophisticated micro/nano structures can provide advanced and useful functions and features as compared with simply smooth surfaces. To promote widespread use of the structured surfaces, manufacturing technology of structured surfaces for ultra-precision dies and moulds made of hardened steel is absolutely essential. Conventional diamond cutting is not applicable to machining of steel due to rapid tool wear and surface deterioration. On the other hand, elliptical vibration cutting (EVC) equipped with the ultra-precision amplitude control sculpturing method is considered as a potential candidate for the functional surface fabrication on steel materials. In this method, tool geometry, especially the clearance angle, imposes a limit on the machinable part geometry due to the flank face contact to the target shape in the downhill machining. In order to clarify the influence of flank face contact on the machining accuracy and the tool wear, a series of theoretical and experimental investigations are conducted in this paper. A surface with micro sine-sweep profile is fabricated on hardened steel by applying the proposed amplitude control sculpturing method. It verified that the interference between flank face and fabricated structure causes not only the serious machining accuracy deterioration but also the serious tool damage due to the enhancing of ploughing process.

Keywords: elliptical vibration cutting; EVC; hardened steel; amplitude control sculpturing method; clearance angle.

DOI: 10.1504/IJNM.2017.087536

International Journal of Nanomanufacturing, 2017 Vol.13 No.4, pp.351 - 361

Received: 15 Sep 2015
Accepted: 17 Jun 2016

Published online: 10 Oct 2017 *

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