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Keywords = single-point diamond cutting (SPDC)

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22 pages, 5230 KiB  
Article
Integrated CAD/CAM Approach for Parametric Design and High Precision Fabrication of Planar Curvilinear Structures
by Jonas T. Churchill-Baird, O. Remus Tutunea-Fatan and Evgueni V. Bordatchev
Micromachines 2025, 16(7), 805; https://doi.org/10.3390/mi16070805 - 11 Jul 2025
Viewed by 296
Abstract
Curvilinear V-grooves are increasingly employed in functional surfaces with applications ranging from fluidics to tribology and optics. Despite their widespread use, the accurate and repeatable fabrication of curvilinear V-grooves remains challenging due to their inherent geometric complexity and the lack of relevant commercial [...] Read more.
Curvilinear V-grooves are increasingly employed in functional surfaces with applications ranging from fluidics to tribology and optics. Despite their widespread use, the accurate and repeatable fabrication of curvilinear V-grooves remains challenging due to their inherent geometric complexity and the lack of relevant commercial CAD/CAM systems. To address this, the present study proposes a CAD/CAM integrated framework capable of automating the design and fabrication of functional surfaces comprising curvilinear V-grooves generated by multi-axis single-point diamond cutting (SPDC). The framework is organized into three main functional blocks supported by seven secondary modules that encompass the entire process from V-groove geometry definition to cutting. The developed framework was practically validated by fabricating sinusoidal V-grooves on a flat surface and testing the capillary flow functionality of a curvilinear pattern. These results demonstrate the relevance of the integrated framework to curvilinear V-groove fabrication, thereby offering a versatile solution for certain types of surface engineering applications. Full article
(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)
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16 pages, 14466 KiB  
Article
Integrated CAD/CAM Approach for Parametric Design and High-Precision Microfabrication of Planar Functional Structures Comprising Radially Oriented V-Grooves
by Jonas T. Churchill-Baird, O. Remus Tutunea-Fatan and Evgueni V. Bordatchev
J. Manuf. Mater. Process. 2025, 9(3), 100; https://doi.org/10.3390/jmmp9030100 - 18 Mar 2025
Viewed by 494
Abstract
High-precision microfabrication is essential for enhancing or enabling new functionalities in parts and tooling surfaces. V-groove structures are commonly used in surface engineering for diverse applications. Selecting the optimal V-groove shape, array, and fabrication method is crucial for achieving the desired performance. This [...] Read more.
High-precision microfabrication is essential for enhancing or enabling new functionalities in parts and tooling surfaces. V-groove structures are commonly used in surface engineering for diverse applications. Selecting the optimal V-groove shape, array, and fabrication method is crucial for achieving the desired performance. This study integrates the parametric definition of V-groove structures in both design and fabrication modules using three main function blocks (MFBs). MFB1 defines a single V-groove’s parametric model using specific input parameters. MFB2 transforms these parameters into equations to generate a CAD model of the surface. MFB3 combines inputs from MFB1 with parameters related to cutting tool geometry, cutting strategy, and process planning, producing functional NC code for the machine tool. The approach focuses on micromachining radial V-grooves on planar surfaces, requiring precise alignment and multi-axis single-point diamond cutting (SPDC) with rotation tool center point (RTCP) support. Testing on acrylic samples achieved ±0.1° orientation accuracy and ±2 μm positional accuracy, demonstrating potential for applications in drag reduction, fouling resistance, light guiding, and open microfluidics. Full article
(This article belongs to the Special Issue Advances in High-Performance Machining Operations)
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