Abstract
The demand for micro-scale surface machining has been steadily increasing, and various methods have been introduced. Among these, microcutting with a diamond tool removes material by making multiple cutting passes. However, many passes are needed to generate micropatterns over a large area. To overcome the drawbacks of this time-consuming process, we propose a novel method, which uses a micropatterned diamond tool. A 220-fs-pulsed Ti: Sapphire laser is used to create micropatterns on the edge line of a rectangular diamond tool. A six-axis motion stage is used to align the edge line and flank surface of the diamond tool with respect to the focal point of the laser beam. Using a simple laser direct-writing method and a 100× objective lens (NA: 0.8), lines ≤ 2 μm in width, 20 μm in length, and 10 μm in separation were fabricated along the 1-mm edge line of a bulk diamond tool. The micropatterned diamond cutting tool was then used to successfully produce micropatterns on the surface of nickel (Ni)-electroformed on SKD-61. This novel process provides an efficient means of multiple micropattern generation for molding applications, such as those required for optics and biotechnology, using only a single pass of a diamond cutting tool.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Lee, Y. C., Chen, B. T., Wu, T. H., and Chou, Y. Y., “Full Wafer Microstructure Fabrication by Continuous UV-Assisted Roller Imprinting Lithography to Enhance Light Extraction of LEDs,” Microelectronic Engineering, Vol. 91, pp. 64–69, 2012.
Sher, M. J., Winkler, M. T., and Mazur, E., “Pulsed-Laser Hyperdoping and Surface Texturing for Photovoltaics,” MRS Bull, Vol. 36, No. 6, pp. 439–445, 2011.
Meng, F., Davis, T., Cao, J., Wang, Q. J., Hua, D., and Liu, J., “Study on Effect of Dimples on Friction of Parallel Surfaces under different Sliding Conditions,” Applied Surface Science, Vol. 256, No. 9, pp. 2863–2875, 2010.
Costa, H. L. and Hutchings, I. M., “Effects of Die Surface Patterning on Lubrication in Strip Drawing,” Journal of Materials Processing Technology, Vol. 209, No. 3, pp. 1175–1180, 2009.
Ramsden, J. J., Allen, D. M., Stephenson, D. J., Alcock, J. R., Peggs, G., and et al., “The Design and Manufacture of Biomedical Surfaces,” CIRP Annals-Manufacturing Technology, Vol. 56, No. 2, pp. 687–711, 2007.
Cao, J., Yuan, W., Pei, Z., Davis, T., Cui, Y., and Beltran, M., “A Preliminary Study of the Effect of Surface Texture on Algae Cell Attachment for a Mechanical-Biological Energy Manufacturing System,” Journal of Manufacturing Science and Engineering, Vol. 131, No. 6, Paper No. 064505, 2009.
Bruzzone, A. A. G., Costa, H. L., Lonardo, P. M., and Lucca, D. A., “Advances in Engineered Surfaces for Functional Performance,” CIRP Annals-Manufacturing Technology, Vol. 57, No. 2, pp. 750–769, 2008.
Brinksmeier, E., Gläbe, R., and Schönemann, L., “Review on Diamond-Machining Processes for the Generation of Functional Surface Structures,” CIRP Journal of Manufacturing Science and Technology, Vol. 5, No. 1, pp. 1–7, 2012.
Mao, S. S., Quéré, F., Guizard, S., Mao, X., Russo, R., and et al., “Dynamics of Femtosecond Laser Interactions with Dielectrics,” Applied Physics A, Vol. 79, No. 7, pp. 1695–1709, 2004.
Gattass, R. R. and Mazur, E., “Femtosecond Laser Micromachining in Transparent Materials,” Nature Photonics, Vol. 2, No. 4, pp. 219–225, 2008.
Shinoda, M., Gattass, R. R., and Mazur, E., “Femtosecond Laser-Induced Formation of Nanometer-Width Grooves on Synthetic Single-Crystal Diamond Surfaces,” Journal of Applied Physics, Vol. 105, No. 5, Paper No. 053102, 2009.
Hsu, E. M., Mailman, N. A., Botton, G. A., and Haugen, H. K., “Microscopic Investigation of Single-Crystal Diamond Following Ultrafast Laser Irradiation,” Applied Physics A, Vol. 103, No. 1, pp. 185–192, 2011.
Pettersson, U. and Jacobson, S., “Tribological Texturing of Steel Surfaces with a Novel Diamond Embossing Tool Technique,” Tribology International, Vol. 39, No. 7, pp. 695–700, 2006.
Kuang, Z., Liu, D., Perrie, W., Edwardson, S., Sharp, M., and et al., “Fast Parallel Diffractive Multi-Beam Femtosecond Laser Surface Micro-Structuring,” Applied Surface Science, Vol. 255, No. 13, pp. 6582–6588, 2009.
Malekian, M., Mostofa, M., Park, S., and Jun, M., “Modeling of Minimum Uncut Chip Thickness in Micro Machining of Aluminum,” Journal of Materials Processing Technology, Vol. 212, No. 3, pp. 553–559, 2012.
Ng, C. K., Melkote, S. N., Rahman, M., and Senthil Kumar, A., “Experimental Study of Micro-and Nano-Scale Cutting of Aluminum 7075-T6,” International Journal of Machine Tools and Manufacture, Vol. 46, No. 9, pp. 929–936, 2006.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kim, J., Je, TJ., Cho, SH. et al. Micro-cutting with diamond tool micro-patterned by femtosecond laser. Int. J. Precis. Eng. Manuf. 15, 1081–1085 (2014). https://doi.org/10.1007/s12541-014-0440-8
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-014-0440-8