Title: Surface topography simulation and roughness prediction of micro-milling single crystal copper

Authors: Xiaohong Lu; Xvdong Sun; Pengrong Hou; Liang Xue; Steven Y. Liang

Addresses: Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China ' The George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, 30332-0405, USA

Abstract: To meet the requirements for assembly accuracy, service life and electric conductivity, the industry usually pursues low surface roughness of single-crystal copper micro-components. The processing and manufacturing of low-surface-roughness single crystal copper micro-components pose new challenges to the process. Micro-milling is an efficient technical way of processing small components with complex three-dimensional topography and low surface roughness. However, the surface forming mechanism of micro-milled single crystal copper is not clear. Based on the theory of trochoidal trajectory of micro-milling cutter, considering the influence of cutter geometry vibration, minimum cutting thickness and other factors. It analysed the formation mechanism of surface topography of single crystal copper micro-milling, and established a surface topography simulation model. The prediction of surface roughness was realised, and conducted a single crystal copper groove milling experiment to prove the effectiveness of the model and prediction.

Keywords: micro-milling; single crystal copper; surface topography; surface roughness; simulation; prediction; cutting trajectory.

DOI: 10.1504/IJNM.2021.121953

International Journal of Nanomanufacturing, 2021 Vol.17 No.2, pp.139 - 153

Accepted: 17 Oct 2021
Published online: 07 Apr 2022 *

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