Force modeling and applications of inclined ball end milling of micro-dimpled surfaces

Functional micro surfaces have been recognized for their vital roles in a wide range of advanced applications. The fabrication of surface structures at the microlevel can be used to influence tribological, optical, and many other surface characteristics. To take advantage of the benefits of functional surfaces, industry and researchers have begun focusing on finding more sustainable and efficient manufacturing processes. The inclined micro ball end milling technique has become a fast and efficient method for creating micropatterned surfaces. With the right adjustments, the spindle speed and feed rate can be set so that the flutes of the cutter create periodic dimpled patterns onto a workpiece surface. This micromachining technique is an ideal method for fabricating dimpled surfaces, especially for metallic alloys such as dies and molds. Developing surface pattern algorithms for generating different dimple geometries can promote a sustainable future for a variety of novel products and lead to accurate manufacturing of surface characteristics. Accurate modeling of cutting forces is important in order to generate desired surface patterns without causing tool breakage and excessive tool deflection. In this study, a mechanistic force model for inclined ball end milling has been proposed and verified for generating micro-dimpled surface. The micro-dimple machining technique is also applied to microinjection molds to create polymeric components with micropatterns. Frictional aspects of both dimpled and inverted dimple surfaces have been investigated. The results indicate that micro-dimple machining combined with microinjection molding is a viable method of producing polymeric components with functional surfaces for advanced technological applications.