In this paper, a new vibration-assisted cutting method is proposed to machine micro grayscale images onto metal freeform surfaces. Taking advantage of a non-resonant vibration complaint cutting device used in a machining system, two vibration components can be used at the same time in the machining process. One vibration component is used to fabricate the freeform surface, while the other to generate the micro grayscale image on the freeform surface. Based on the working principle of this method, a toolpath generation algorithm is developed by considering the toolpath components for both the grayscale image and the freeform surface. Using the generated toolpath, image machining experiments have been conducted. Images have been successfully machined on saddle surfaces with an average surface roughness of 169 nm, which demonstrates the capability of the proposed method. This technology has potentially wide applications in machining master molds for mass production of patterned plastic components or drugs in the anti-counterfeiting field.

本文提出了一种新的振动辅助切割方法，将微灰度图像加工到金属自由曲面上。利用在加工系统中使用的非共振振动投诉切割设备，可以在加工过程中同时使用两个振动分量。一种振动分量用于制造自由曲面，而另一种振动分量用于在自由曲面上生成微灰度图像。基于该方法的工作原理，通过考虑灰度图像和自由曲面的刀具路径分量，开发了刀具路径生成算法。使用生成的刀具路径，进行了图像加工实验。图像已成功在鞍形表面上进行了机械加工，平均表面粗糙度为169 nm，证明了所提出方法的能力。这项技术在防伪领域中用于批量生产带图案的塑料部件或药品的母模加工中具有广泛的应用前景。