Analysis of structural integrity of special purpose miniaturised machine tool and performance evaluation for micro machining applications

The function of a machine tool is to move the cutting tool along a defined trajectory with sufficient accuracy and precision against cutting forces arising from the material removal processes such as milling, drilling and turning. This paper describes the analysis of the structural integrity of the miniaturised machine tool (MMT) specially developed for micro-machining applications. Finite element simulation methodology is carried out in the development stage using commercial finite element program ANSYS. The results of the simulation studies are presented as responses of the machine tool structure to the forces acting on it in terms of deformation and stress. Also presented are the results of natural frequency analysis and modes shapes of the machine tool structure. The performance of the miniaturised machine tool is finally verified using micro-cutting tests. The geometrical accuracies of the micro-milled channels and micro NAS test part features confirm the suitability of the developed machine tool for micro-cutting operations.