Permutations of 2D assisted vibration and 1D primary fly-cutting to generate hierarchical micro-textures

The hierarchical micro-textures are usually fabricated by ultra-precision machining technology, specially the fast tool servo (FTS) and slow tool servo (STS) technologies are widely employed in the fabrication of hierarchical micro-textures with their advantages of high frequency and high precision. However, both FST and STS techniques suffer from the problem of insufficient frequency response during the machining of linear micro-grooves and high-strain curvature micro-nanostructures. Therefore, this paper develops a two-dimensional vibration-assisted cutting technology (VACT) based on the primary cutting motion of fly-cutting and studies the permutations of 2D vibration-assisted and 1D primary fly-cutting to generate hierarchical micro-textures. Firstly, the effects of machining parameters on the microgroove structures under the X/Z-direction excitations were investigated, and the machined morphology of micro-groove structures superimposed lens (MMSL) under the X/Z-direction excitations was analyzed. Secondly, the effects of machining parameters on the microgroove structures under the Y/Z-direction excitations were investigated, and the surface morphology of MMSL under the Y/Z-direction excitations was analyzed. Finally, the effect of sinusoidally excited vibration in the X/Y-directions on the surface microstructure of machined straight grooves was studied, and the surface morphology of MMSL under the X/Y-direction excitations was analyzed. This study expands the application range of three-axis machine tools and provides an effective way to generate hierarchical micro-textures. • A machining platform by permuting 2D assisted vibration and 1D primary fly-cutting has been developed. • The structure of the MMSL under the X/Z-direction excitation exhibits insect compound eyes microstructures. • The structure of the MMSL under the Y/Z-direction excitation exhibits insect wing-like microstructures. • The structure of the MMSL under the X/Y-direction excitation exhibits wavy microstructures. • Adjustment of the position and period of hierarchical micro-textures can be realized by changing the machining parameters.