Skip to main content
SpringerLink
Log in

Design of a truss-structured compliant toolholder for machining of structured surfaces

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Cutting toolholders, with designed in-built compliant mechanisms, are frequently used for machining microfeatures. In this paper, compliant structures are designed using trusses as they exhibit a superior strength-to-weight ratio. Systematically stacked two-stage truss structures along with flexure hinges are designed to yield the desired precise cutting motion. The materially reduced efficient design amplifies the output force and greatly assists in overcoming cutting resistance during machining. The characteristics of the designed compliant tool holder are analysed by considering the output force and displacement for a given input. Both mathematical modelling to determine the force and finite element analysis to identify the critical stress regions when subjected to a prescribed input displacement are presented. As part of dynamic analysis, modal analysis and harmonic response studies were performed to determine how the trussed compliant structure deforms when subjected to dynamic loadings. The designed tool holder was additively manufactured using functionally rigid polyamide-12-glass-bead (PA12-GB) material. The performance of the developed cutting tool holder is then verified by machining radially graded surfaces following which, the machining results are presented in this paper.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Data availability

All data generated or analysed during this study are included in this published article.

Code availability

Not applicable.

References

  1. Whitesides GM (2006) The origins and the future of microfluidics. Nature 442:368–374. https://doi.org/10.1038/NATURE05058

    Article  Google Scholar 

  2. Singh SK, Mali HS (2019) Microfeatures and microfabrication: current role of micro-electric discharge machining. J Micromech Microeng 29:043002. https://doi.org/10.1088/1361-6439/AB0249

    Article  Google Scholar 

  3. Hejun H, Bogue R (2007) MEMS sensors: past, present and future. Sens Rev 27:7–13. https://doi.org/10.1108/02602280710729068

    Article  Google Scholar 

  4. Nosonovsky M, Bhushan B (2007) Biomimetic superhydrophobic surfaces: multiscale approach. Nano Lett 7:2633–2637. https://doi.org/10.1021/NL071023F

    Article  Google Scholar 

  5. Li Y, Junhu Z, Shoujun Z, Heping D, Fei J, Zhanhua W, Zhiqiang S, Liang Z, Yang L, Li Haibo X, Weiqing YB (2009) Biomimetic surfaces for high-performance optics. Adv Mater 21:4731–4734. https://doi.org/10.1002/ADMA.200901335

    Article  Google Scholar 

  6. Putignano C, Parente G, Profito FJ, Gaudiuso C, Ancona A, Carbone G (2020) Laser microtextured surfaces for friction reduction: does the pattern matter? Materials (Basel) 13:1–21. https://doi.org/10.3390/MA13214915

    Article  Google Scholar 

  7. An H, Wang S, Li D, Peng Z, Chen S (2021) Self-cleaning performance of the micropillar-arrayed surface and its micro-scale mechanical mechanism. Langmuir 37:10079–10088. https://doi.org/10.1021/ACS.LANGMUIR.1C01398/SUPPL_FILE/LA1C01398_SI_006.AVI

    Article  Google Scholar 

  8. Zhao W, Xiao L, He X, Cui Z, Fang J, Zhang C, Li X, Li G, Zhong L, Zhang Y (2021) Moth-eye-inspired texturing surfaces enabled self-cleaning aluminum to achieve photothermal anti-icing. Opt Laser Technol 141:107115. https://doi.org/10.1016/j.optlastec.2021.107115

    Article  Google Scholar 

  9. Birman V, Byrd LW (2007) Modeling and analysis of functionally graded materials and structures. Appl Mech Rev 60:195–216. https://doi.org/10.1115/1.2777164

    Article  Google Scholar 

  10. Xu Y, Peng P (2015) High quality broadband spatial reflections of slow Rayleigh surface acoustic waves modulated by a graded grooved surface ARTICLES YOU MAY BE INTERESTED IN. J Appl Phys 117:35103. https://doi.org/10.1063/1.4905948

    Article  Google Scholar 

  11. Liao B, Feng Xia R, Li W, Lu D, Jin ZM (2021) 3D-printed Ti6Al4V scaffolds with graded triply periodic minimal surface structure for bone tissue engineering. J Mater Eng Perform 30. https://doi.org/10.1007/s11665-021-05580-z

  12. Brinksmeier E, Karpuschewski B, Yan J, Sch L (2020) Manufacturing of multiscale structured surfaces. CIRP Ann - Manuf Technol 69:717–739. https://doi.org/10.1016/j.cirp.2020.06.001

    Article  Google Scholar 

  13. Totsu K, Fujishiro K, Tanaka S, Esashi M (2006) Fabrication of three-dimensional microstructure using maskless gray-scale lithography. Sensors Actuators A Phys 130–131:387–392. https://doi.org/10.1016/J.SNA.2005.12.008

    Article  Google Scholar 

  14. Park J, Fujita H, Kim B (2011) Fabrication of metallic microstructure on curved substrate by optical soft lithography and copper electroplating. Sensors Actuators A 168:105–111. https://doi.org/10.1016/j.sna.2011.03.024

    Article  Google Scholar 

  15. Cai Y, Chang W, Luo X, Sousa AML, Hang K, Lau A, Qin Y (2018) Superhydrophobic structures on 316L stainless steel surfaces machined by nanosecond pulsed laser. Precis Eng 266. https://doi.org/10.1016/j.precisioneng.2018.01.004

  16. Gao T, Xu Z, Fang F, Gao W, Zhang Q, Xu X (2012) High performance surface-enhanced Raman scattering substrates of Si-based Au film developed by focused ion beam nanofabrication. Nanoscale Res Lett 7:1–8. https://doi.org/10.1186/1556-276X-7-399/FIGURES/7

    Article  Google Scholar 

  17. Büttner H, Roth R, Wegener K (2018) Limits of die-sinking EDM for micro structuring in W300 steel with pure copper electrodes. Procedia CIRP 77:646–649. https://doi.org/10.1016/J.PROCIR.2018.08.186

    Article  Google Scholar 

  18. Lim HS, Wong YS, Rahman M, Edwin Lee MK (2003) A study on the machining of high-aspect ratio micro-structures using micro-EDM. J Mater Process Technol 140:318–325. https://doi.org/10.1016/S0924-0136(03)00760-X

    Article  Google Scholar 

  19. Uhlmann E, Perfilov I (2018) Machine tool and technology for manufacturing of micro-structures by micro dry electrical discharge milling. Procedia CIRP 68:825–830. https://doi.org/10.1016/J.PROCIR.2017.12.163

    Article  Google Scholar 

  20. Lucca DA, Klopfstein MJ, Mejia OR, Rossettini L, Deluca LT (2013) Investigation of ammonium perchlorate by nanoindentation investigation of ammonium perchlorate by nanoindentation. Mater Sci Technol. https://doi.org/10.1179/174328406X83996

  21. Yan J, Imoto Y (2018) Nanoscale surface patterning of diamond utilizing carbon diffusion reaction with a microstructured titanium mold. CIRP Ann 67:181–184. https://doi.org/10.1016/J.CIRP.2018.04.067

    Article  Google Scholar 

  22. Zhang N, Zhang H, Stallard C, Fang F, Gilchrist MD (2018) Replication integrity of micro features using variotherm and vacuum assisted microinjection moulding. CIRP J Manuf Sci Technol:20–38. https://doi.org/10.1016/j.cirpj.2018.10.002

  23. Rosenkranz A, Szurdak A, Gachot C, Hirt G, Mücklich F (2015) Friction reduction under mixed and full film EHL induced by hot micro-coined surface patterns. Tribol Int 95:290–297. https://doi.org/10.1016/j.triboint.2015.11.035

    Article  Google Scholar 

  24. Brinksmeier E, Riemer O, Schönemann L, Zheng H, Böhmermann F (2014) Microstructuring of surfaces for bio-medical applications. Adv Mater Res 907:213–224. https://doi.org/10.4028/WWW.SCIENTIFIC.NET/AMR.907.213

    Article  Google Scholar 

  25. Zhang J, Cui T, Ge C, Sui Y, Yang H (2016) Review of micro/nano machining by utilizing elliptical vibration cutting. Int J Mach Tools Manuf 106:109–126. https://doi.org/10.1016/J.IJMACHTOOLS.2016.04.008

    Article  Google Scholar 

  26. Zhu L, Li Z, Fang F, Huang S, Zhang X Review on fast tool servo machining of optical freeform surfaces. Int J Adv Manuf Technol 95:2071–2092. https://doi.org/10.1007/s00170-017-1271-4

  27. Gao W, Araki T, Kiyono S, Okazaki Y, Yamanaka M (2003) Precision nano-fabrication and evaluation of a large area sinusoidal grid surface for a surface encoder. Precis Eng 27:289–298. https://doi.org/10.1016/S0141-6359(03)00028-X

    Article  Google Scholar 

  28. Liu Q, Zhou X, Xu P, Zou Q, Lin C (2012) A flexure-based long-stroke fast tool servo for diamond turning. Int J Adv Manuf Technol 59:859–867. https://doi.org/10.1007/s00170-011-3556-3

    Article  Google Scholar 

  29. Brecher C, Lange S, Merz M, Niehaus F, Wenzel C, Winterschladen M (2006) NURBS based ultra-precision free-form machining. CIRP Ann - Manuf Technol 55:547–550. https://doi.org/10.1016/S0007-8506(07)60479-X

    Article  Google Scholar 

  30. Brinksmeier E, Riemer O, Gläbe R, Lünemann B, Kopylow CV, Dankwart C, Meier A (2010) Submicron functional surfaces generated by diamond machining. CIRP Ann - Manuf Technol 59:535–538. https://doi.org/10.1016/j.cirp.2010.03.037

    Article  Google Scholar 

  31. Brinksmeier E, Preuss W (2013) How to diamond turn an elliptic half-shell? Precis Eng 37:944–947. https://doi.org/10.1016/J.PRECISIONENG.2013.04.002

    Article  Google Scholar 

  32. Kong L, Cheung C, Wang B, Ho L (2014) A theoretical and experimental investigation of design and slow tool servo machining of freeform progressive addition lenses (PALs) for optometric applications. Int J Adv Manuf Technol 72:33–40. https://doi.org/10.1007/s00170-013-5215-3

    Article  Google Scholar 

  33. Mukaida M, Yan J (2017) Ductile machining of single-crystal silicon for microlens arrays by ultraprecision diamond turning using a slow tool servo. Int J Mach Tools Manuf 115:2–14. https://doi.org/10.1016/J.IJMACHTOOLS.2016.11.004

    Article  Google Scholar 

  34. Zhu ZH, Chen L, Niu Y, Pu X, Huang P, To S, Zhu L, Zhu Z (2021) Tri-axial fast tool servo using hybrid electromagnetic-piezoelectric actuation for diamond turning. IEEE Trans Ind Electron 69(2):1728–1738. https://doi.org/10.1109/TIE.2021.3060635

    Article  Google Scholar 

  35. Jung H, Hayasaka T, Shamoto E, Ishii H, Ueyama T, Hamada S (2021) “Multimode vibration cutting” – a new vibration cutting for highly-efficient and highly-flexible surface texturing. Precis Eng 72:111–121. https://doi.org/10.1016/J.PRECISIONENG.2021.04.003

    Article  Google Scholar 

  36. Gao W, Tano M, Araki T, Kiyono S (2006) Precision fabrication of a large-area sinusoidal surface using a fast-tool-servo technique-improvement of local fabrication accuracy-*. JSME Int J Ser C 49(4):1203–1208

    Article  Google Scholar 

  37. Wallach JC, Gibson LJ (2001) Mechanical behavior of a three-dimensional truss material. Int J Solids Struct 38:7181–7196. https://doi.org/10.1016/S0020-7683(00)00400-5

    Article  MATH  Google Scholar 

  38. Hopkins JB, Culpepper ML (2010) Synthesis of multi-degree of freedom, parallel flexure system concepts via freedom and constraint topology (FACT) - part I: principles. Precis Eng 34:259–270. https://doi.org/10.1016/j.precisioneng.2009.06.008

    Article  Google Scholar 

  39. Qin Y, Shirinzadeh B, Zhang D, Tian Y (2013) Compliance modeling and analysis of statically indeterminate symmetric flexure structures. Precis Eng 37:415–424. https://doi.org/10.1016/j.precisioneng.2012.11.004

    Article  Google Scholar 

  40. Kim JJ, Choi YM, Ahn D, Hwang B, Gweon DG, Jeong J (2012) A millimeter-range flexure-based nano-positioning stage using a self-guided displacement amplification mechanism. Mech Mach Theory 50:109–120. https://doi.org/10.1016/j.mechmachtheory.2011.11.012

    Article  Google Scholar 

  41. Song X, Feih S, Zhai W, Sun CN, Li F, Maiti R, Wei J, Yang Y, Oancea V, Romano Brandt L, Korsunsky AM (2020) Advances in additive manufacturing process simulation: residual stresses and distortion predictions in complex metallic components. Mater Des 193:108779. https://doi.org/10.1016/J.MATDES.2020.108779

    Article  Google Scholar 

  42. Cano AJ, Salazar A, Rodríguez J (2018) Effect of temperature on the fracture behavior of polyamide 12 and glass-filled polyamide 12 processed by selective laser sintering. Eng Fract Mech 203:66–80. https://doi.org/10.1016/j.engfracmech.2018.07.035

    Article  Google Scholar 

  43. Cao F, Cui M, Li J (2018) Modal analysis and harmonic response analysis of crane arm of medium and small sized automobile crane. In: In2018 3rd International Conference on Advances in Materials, Mechatronics and Civil Engineering (ICAMMCE 2018). Atlantis Press, pp 151–155. https://doi.org/10.2991/ICAMMCE-18.2018.35

    Chapter  Google Scholar 

Download references

Acknowledgements

The diamond turning experiments were conducted with the assistance of Mr Yeo Eng Huat from NUS’s Advanced Manufacturing Lab.

Funding

This research was funded by Singapore’s Ministry of Education. Funding number R 265-000-690-114.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National University of Singapore, 9 Engineering, Drive 1, 10 Kent Ridge Crescent, 117575, Singapore

    Vinodth Paniselvam & A. Senthil Kumar

Authors
  1. Vinodth Paniselvam
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. Senthil Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

All authors have contributed equally to every aspect of this research.

Corresponding author

Correspondence to A. Senthil Kumar.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

All authors were fully involved in the study and preparation of the manuscript. Each of the authors has read and concurs with the content in the final manuscript.

Consent for publication

All authors have read and agreed to the terms and conditions for publication.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Paniselvam, V., Kumar, A.S. Design of a truss-structured compliant toolholder for machining of structured surfaces. Int J Adv Manuf Technol 126, 3489–3501 (2023). https://doi.org/10.1007/s00170-023-11321-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-11321-4

Keywords

Search

Navigation