Study On The Grinding Technology Of Single Blade Micro Miller

With the increasing need of microminiaturized products in the field of nationaldefense and civilian applications such as aerospace field, researchers at home andabroad pay more and more attention to the micro milling technology. As an importantpart of the micro milling technology, the micro miller becomes the research hotspot ofmany researchers. Nowadays, most commercialized micro millers are made of hardalloy. However, in view of that the natural monocrystalline diamond has many goodproperties such as high hardness, wear resistance, high-thermal conductivity, lowthermal expansion coefficient etc, micro millers made of the natural monocrystallinediamond will become the research hotspot in this area. As the manufacturing technologyof the high-precision natural monocrystalline diamond miller refers to top end industry,the abroad treats us with blockade in this area. In view of the huge need ofmicrominiaturized products nowadays, this paper does some research on themanufacturing technology of the diamond millers by designing and producing micromillers made of the natural monocrystalline diamond.Firstly, this paper discusses directional technique of the natural monocrystallinediamond, and chooses the (100) crystal plane of the regular hexahedron monocrystallinediamond as the miller’s the rake face and the flank face. And reasonable tool angles aredesigned, the rake angle is0°and the clearance angle is6°. At the same time, thestability of the miller while it is rotating and the interference of the cutting edge isanalysed in this paper; the miller is3-D modeled, whose structure is optimized throughthe structural analysis and the modal analysis.Secondly, in order to improve the miller’s quality, this paper does the grindingprocess test on a cutter whose rake face and the flank face are both the (100) crystalplane. The test takes full account of the PG3B machine tool and the background ofgrinding the micro miller, some elements such as the diamond wheel size, the grindingpressure of the cutter, the main shaft speed, the one-way movement schedule, therecycle transport period and the distance from the axis of rotation are analysed in thetest. The effect trend of these elements to the experimental index is got, which makesthe optimum technique parameters achieved.Thirdly, some kinds of the tool tip of the micro miller with one cutting edge are designed; grooving at the end of the shank is carried out by the laser cutting machine;and the diamond is fixed on the shank by the vacuum brazing technology; and theturning radius of the miller is reduced on the PG3B machine tool with the ceramic bonddiamond wheel; a single blade diamond micro miller whose diameter is0.8mm has beenfabricated successfully in the end, which means that a complete manufacturing processhas been set up.At last, a micro milling test is carried out with the micro miller made before, andthis paper contrasts the groove processed by the diamond micro miller with the grooveprocessed by the commercial hard alloy miller. It is found that quality of the grooveprocessed by the diamond micro miller is better than the one processed by the hard alloymiller in some way. To solve the problem found in the micro milling test, a change ismade on the miller’s structure, and it works.