Generation of discontinuous microstructures by Diamond Micro Chiseling

Diamond Micro Chiseling (DMC) is a new machining process to generate discontinuous microstructures, such as miniaturized cube corner retroreflectors or V-shaped grooves with defined endings. After a brief introduction to the process itself, this paper presents an in-depth analysis of factors that determine the achievable size and performance of such microstructures. The capability for generating discontinuous microstructures is assessed theoretically by considering the process kinematics and the diamond tool design by geometrical calculations. Thereafter, an experimental evaluation of the process is presented by showing measured data for cutting forces, achievable shape accuracy and surface finish for different structure sizes.