Abstract
Micro end mills made of hard or ultra-hard materials are mainly fabricated by grinding or by wire electrical discharge machining (WEDM). However, with the advances of new tool materials from ultra-hard to super-hard together with lower or no electrical conductivity such as the material of nano-polycrystalline diamond, the grinding or the WEDM method cannot be used for machining due to their ultra-low process efficiencies for such materials. Laser machining has been tested an effective method. Accordingly, multi-axis laser machines need to be designed for micro tool fabrications. In the paper, a typical micro ball end mill with relatively complex features has been analyzed by the generative design method to generate the number and properties of needed motion axes. Based on the analysis, a novel five-axis laser machine has been designed. Aiming at high-quality micro tool fabrications, the kinematics model has been derived for this five-axis laser machine and error budge has been studied for the subsequently optimum selection of key motion components.
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Acknowledgment
The authors wish to express their appreciation for the financial support by the China National Science and Technology Key Project “High Quality CNC Machine Tools and Fundamental Manufacturing Equipements” with the grant number of 2009ZX04014-032 and by the Natural Science Foundation of Shandong Province, China with the grant number of ZR2011EEM010.
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Cheng, X., Huang, Y., Zhou, S. et al. Study on the generative design method and error budget of a novel desktop multi-axis laser machine for micro tool fabrications. Int J Adv Manuf Technol 60, 545–552 (2012). https://doi.org/10.1007/s00170-011-3630-x
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DOI: https://doi.org/10.1007/s00170-011-3630-x