Study on 5-axial milling on microstructured freeform surface using the macro-ball cutter patterned with micro-cutting-edge array

A 5-axial micro-replication milling of microstructured freeform surface is proposed by a novel ball cutter, on which micro-cutting-edge array is patterned by a diamond wheel V-tip in micro-grinding. It can efficiently and precisely machine arbitrary-curved microgroove and micro-pyramid arrays on aluminium alloy and die steel. The form errors reach 6.6 μm in 253.6 μm in microstructure depth and 1.6 μm with 50 mm in macro-freeform, respectively. The rake angle, however, is decreased so as to increase cutting temperature. Moreover, increasing wheel speed and decreasing feed speed decrease micro-form errors and surface roughness. The cross-spark-out cutting may deburr.