Strategy and error analysis for machining the designed microstructured surfaces by structured grinding wheels

In this research, a strategy to design structured grinding wheels to machine designed structured surfaces in micro-scale through the grinding process is investigated. Firstly, the geometry of the microstructured surface is defined. A mathematical model to describe the geometry of the structured grinding wheel and the grinding parameters is presented according to the geometry of the designed microstructures on the workpiece surface. And then, several operating conditions for the grinding operation are mathematically determined and kinematically simulated using a proper programming language to produce the designed geometry of the microstructured surface. The errors in the simulated geometries of the machined microstructures are calculated and analyzed. Finally, the reasons for deviation and ability to minimize error sources are investigated.