Research on surface quality and tool wear of micro-groove array machined by a novel micro-milling cutter

The regular pattern and periodic arrangement of the micro-groove array structure endow the material with unique and excellent functional properties, such as friction lubrication and optical diffraction, which are widely used in aerospace, optical engineering, and other fields. However, the contradiction between the machining quality, efficiency, and cost of the micro-groove array always exists due to their small size, large number, and high uniformity. In this study, a novel micro-milling cutter for machining micro-groove array is manufactured by low-speed wire electrical discharge turning (LS-WEDT) process technology. The cutting experiment of nickel-based single-crystal superalloys was carried out. The tool manufacturing process, micro-groove array machining and forming method, micro-groove surface characteristics, and the tool wear were investigated. The results show that the surface of the micro-groove array machined by the novel micro-milling cutter has high surface uniformity and low surface roughness. This research further enriches the manufacturing methods of micro-groove array.