Development of a PC-based control system for a five-axis ultraprecision micromilling machine ‘Ultra-Mill’ and its performance assessment

Abstract

In the realm of micro- and nanomachining, high-precision three-dimensional miniaturized components and microstructures from an extensive range of engineering materials are increasingly required in industries such as optics, automotive, medical, aerospace, and defence. Five-axis ultraprecision micromilling machines are essential for manufacturing components and microstructures for these industries. This paper presents the design and development of the control system for a five-axis ultraprecision micromillling machine – Ultra-Mill – and its performance assessment based on two application case studies. The design specifications of Ultra-Mill are based on motion and positioning accuracy, dynamic stiffness, thermal stability, and online monitoring and inspection requirements, which are heavily dependent on the control system for the micromilling machine and associated micromilling processes. The implementation and application perspectives of the control system are therefore presented in relation to the ultraprecision and micro/nano feature capability of the machine and process, including controller dynamics, driver and actuation dynamics, feedback dynamics, online inspection and monitoring, and software dynamics.