Direct scribing of metal microgratings using sawtoothed cemented carbide tools with Johnson-Cook model-based plastic deformation simulation
Year: 2025
Type: article
Abstract: We demonstrate the continuous and scalable precision machining of metal micrograting structures by developing the DISCRIM (DIrect SCRIbing of Metals) process which utilizes direct mechanical scribing of the sawtooth-patterned cemented carbide edge over a metal workpiece. The tool's edge is fabricated via sequential micro-grinding using a conical polycrystalline diamond tip prepared by wire electrical discharge machining. When the tool edge contacts the metal surface at the correct angle, it can be linearly fed under controlled force, temperature, and scribing speed to continuously scribe multiple microgrooves on the metal surface in a single stroke. We show that the machining depth and profile of the metal microgratings can be tailored by adjusting key DISCRIM parameters, in this case, contact force, temperature, and scribing speed. Finite element analysis and friction model-based simulations further elucidate the deformation behavior of the metal surface under these controlled conditions. The DISCRIM process requires a very small area (edge) of a high-hardness tool and linearly proceeds at moderate conditions without resorting to its high-speed rotation, thereby enabling durable and high-throughput machining of large-area metal microstructures without noticeable tool wear. The DISCRIM process offers scalable microstructuring for diverse applications, including mechanical and aerospace components and electronic and photonic elements.
Source: Materials & Design
Authors: Minwook Kim, Dae Bo Sim, Yong Tae Kim, Bo Hyun Kim, Jong G. Ok
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,650
OpenAlex ID: W7077059648