Dynamics design optimization and experimental validation of a miniaturized machine tool for micro-milling

This paper presents a 3-axis miniaturized machine tool for micro-milling in terms of dynamics design and structural optimization. Four different machine tool structure forms are proposed and contrasted in conceptual and fundamental design stage. The best one is selected and optimized to improve the dynamic performance of the machine tool. The measuring errors are also considered in the design stage and the influence from the location of the detecting element on the measuring error is also discussed and optimized. The modal test and the prediction of the milling chatter vibration stability is carried out. An experimental prototype of miniaturized numerical control milling machine was developed according to the design and optimization results. Machining trials have been carried out by the tungsten carbide micro-diameter cutter on the polymethylmethacrylate and the lead brass (HPb63-3) surfaces. The results from the micro-milling validate the theoretical models and analysis very well and provide the evidence of the approach being helpful to design the miniaturized machine tool for micro-machining.