In the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual trochoidal trajectories of the cutting edge on micro-milling forces should also be considered comprehensively. In this paper, the tool runout error in the micro-milling process is first analysed, and an instantaneous undeformed chip thickness model is established considering the runout error. On this basis, the dynamic deformation of the micro-cutting tool and thin-walled micro-part is studied, and an instantaneous, undeformed, chip-thickness model is proposed with the consideration of both the runout error and dynamic deformation. The dynamic parameters of the machining system are obtained using the receptance coupling method. Finally, thin-walled micro-part machining experiments are carried out, and the obtained results of micro-milling force simulation based on the proposed model are compared with the experimental results. The results indicate that the micro-milling force modelling, by taking the influence of machining dynamics into account, has better prediction accuracy, and the difference between the predicted resultant forces and the experimental results is less than 11%.

As the applications for freeform optical surfaces continue to grow, the need for high-precision machining methods is becoming more and more of a necessity. Different toolpath strategies for the ultra-high precision turning of freeform surfaces can have a significant impact on the quality of the machined surfaces. This paper presents a novel toolpath planning method for ultra-precision slow tool servo diamond turning based on the curvature of freeform surfaces. The method analyzes the differential geometric properties of freeform surfaces by reconstructing NURBS freeform surfaces. A mathematical model is constructed based on the parameters of different positions of the freeform surface, toolpath parameters, and tool residual height. Appropriate toolpath parameters can be calculated to generate the optical freeform ultra-precision slow tool servo diamond turning toolpath. Compared with the toolpaths generated by the traditional Archimedes spiral method, the ultra-precision slow tool servo diamond turning toolpath planning method proposed in this paper can generate more uniform toolpaths on the freeform surfaces and keep the residual tool height within a small range.

Micro-milling has found extensive applications in machining components with thin-walled microstructures, such as terahertz slow-wave structures, microfluidic chips, and micro-molds. Due to the influence of size effects, micro-milling exhibits higher specific energy consumption compared with traditional milling, implying that more energy is consumed to remove a unit volume of material, particularly in challenging-to-machine materials like Ti-6Al-4V. Historically, research on parameter optimization for micro-milling has predominantly focused on enhancing machining quality and efficiency, with limited attention given to energy efficiency. However, in the context of the “double carbon” strategy, energy conservation and emissions reduction have garnered significant attention in the manufacturing industry. Therefore, this paper proposes a micro-milling parameter-based power consumption model. Based on this, a specific energy consumption model can be obtained. Moreover, evolutionary algorithms are utilized for the optimization of micro-milling parameters, which aims to achieve comprehensive enhancements in both machinability and sustainability. The optimization objectives encompass improving surface quality, dimensional accuracy, material removal rate, and specific energy consumption during the micro-milling process for thin-walled micro-structures. Among them, NSGA-III achieves the best optimization results. Under conditions in which cutting energy consumption and processing efficiency are very close, the optimization outcomes based on NSGA-III lead to the best machining quality, including the minimum surface roughness and dimensional errors, and the largest surface fractal dimension. The optimal combination of micro-milling parameters is n = 28,800 rpm, f_z = 2.6 μm/t, and a_p = 62 μm.

The high performance of optical components is contingent upon the quality of their optical surfaces, thereby imposing elevated standards on the methodologies employed for their fabrication. This study involved experimental research on freeform optical surface elements of polymethyl methacrylate with nano-surface roughness. In this study, the effects of machining parameters of ultra-precision slow tool servo turning on the surface roughness of different types of areas of freeform optical surfaces in the finishing stage were analysed. Based on the analysis of ultra-precision turning test results for freeform optical surfaces, a novel evaluation method for surface quality is proposed to assess the overall uniformity of surface quality across the entire freeform optical surface. Building upon this proposed evaluation method for overall surface quality uniformity, the processing method of high-quality freeform optical surfaces is studied. The results show that in the finishing stage, the radial feed rate exerts the greatest influence on the surface roughness of the freeform optical surface, especially the surface roughness of the concave surface area. This will exacerbate the surface quality inhomogeneity of the freeform optical surface. Based on the analysis results, optimal machining parameters were selected for processing trials. Concurrently, additional machining tests were conducted to further validate the influence of radial feed rate. Ultimately, a nano-scale PMMA freeform optical surface with uniform overall surface quality was achieved. The variation in surface roughness in different regions of the optical freeform is regulated to stabilise within 2 nm on the surface of polymethyl methacrylate. The overall uniformity of surface quality across the entire freeform optical surface was maintained at a high level.