The Development Of The Miniature 5-axis Micro-milling Machine Tool

The requirements for micro-product is becoming more and more demanding in recent years in the field like biotechnology, modern healthcare, microelectronics industry, etc. The feature size of this kind of products varies mainly between 0.01 mm and 10 mm. As the irregular and complicated surface and various machining materials, it is hard to machine for some typical processing crafts like laser etching technique and LIGA. Though precision and ultra-precision machine tool play a crucial role in ultra-precision machining, this kind of processing craft is costly and has many drawbacks like lack of flexibility and low efficiency. Miniaturization of machining tool is becoming the key to this problem.In order to achieve the machining of three-dimensional parts, a five-axis micro-milling machine tool will be designed in this research firstly which includes type selection and the building of the hardware platform. The solid modeling of the micro-milling machine tool will be completed and after modal analysis of the system, the dynamic property of the system will be obtained to analyze its mechanical property. Based on the testing result of laser-Doppler-scanning-vibrometer on the hardware structure in extreme condition, the stability of the system can be demonstrated.After building the hardware system, an open control system based on multi-axis controller UMAC is designed to achieve machining. To optimize the servo property of each axis, response characteristics will be analyzed in the research. Then by adjusting the parameters of PID, a better servo property of each axis can be achieved. At last, to achieve the machining of three-dimensional parts and to convenience man-machine interaction, a software in modularization structure is developed based on Visual C#. After testing the human-computer interaction face on the machine, the faculty of the software is verified.To achieve the auto-programming of three-dimensional parts, the movement property of the machine is analyzed. Based on the result, the transformational relation of cutter location coordinate between workpiece coordinate system and machine coordinate system can be calculated. The post-processing of machine program is based on the relationship. The influence of kinematic error to machining accuracy is analyzed in the research. And the position error is detected and compensated. Post-processing model of NC program is developed based on MATLAB, and auto-programming is achieved by NX UG8.5. To verify the NC program, the structure of the machine tool is build based on VERICUT. At last, by doing machining lab, the machining property of the machine tool is tested.