Chips and Tips

David J.古肯贝格尔^一,西奥多斯E德格鲁特^一,Alwin M.D.万²,David J.Beebe^一Edmond W.K.Young^2，*

^一生物医学工程系，Wisconsin Institutes for Medical Research,University of Wisconsin-Madison,麦迪逊，WI美国

²机械工业工程系，University of Toronto,国王学院路5号，MC313,Toronto,在，加拿大。

*通讯作者，E-mail: eyoung@mie.toronto.ca;电话：+1（416）978 1521

为什么这个有用？

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…………………………Micromilling is a highly efficient method for fabricating microfluidic devices directly in polymeric materials like thermoplastics.请参阅Guckenberger及其同事的评论文章，了解微加工的入门知识。^一将工件固定在铣床工作台上后，²铣削过程的下一步是align the tool对于工件，从而定义坐标原点。Many high-end mills designed for micromilling have automated tool alignment systems.然而，也能研磨微装置的低成本研磨机可能没有刀具对准系统，因此，用户必须手动将工具对准工件，以达到所需的精度。Here we present several alignment techniques that are low cost and can be performed by minimally trained users.We divide tool alignment into two separate directions: the verticalz-轴方向，and the planarX-Yplane direction.

What do I need?

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• 数控铣床（PCNC 770，Tormach)
• 工具，e.g.选择的端铣刀
• Workpiece (properly secured to milling table,see ref.〔2〕

每种技术所需的特定工具或材料在下文单独引用。under the "Tooling Note".

What do I do?

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Z轴方向

Fig.1。Four techniques for aligning the tool to the workpiece in thez-axis (from left to right): (i) reflection,（ii）芯片，(iii) paper,和（iv）夹头技术。

Tooling Note: This technique requires a reflective surface (e.g.,transparent materials such as PS or PMMA),but otherwise does not require any specific tooling.

步骤1：从稍微高于工件的刀尖开始，with the spindle turned off.
步骤2：从工件的近平面位置看，lower the tool until the tool itself comes in contact with its reflection.
Step 3:将此位置设置为z= 0.

Tip:         Placing a piece of paper behind the tool will improve contrast,making it easier to identify when the tool contacts the reflection.A magnifying glass can be used to improve visibility.

Tooling Note: This technique does not require any specific tooling.

步骤1：在主轴运转的情况下，从稍微高于表面的工具开始。（即。，工具应旋转）。
步骤2：Lower the tool towards the surface until either (a) a chip is observed,(b) a mark is made on the surface,or (c) a sound is made from the tool cutting the material.
Step 3:将此位置设置为z= 0.

提示：这种方法最适合大型和平板立铣刀，and can be more difficult with small endmills or any tool that is pointed or round at the tip.注意，这是一种物理接触方法，会使表面有瑕疵。

Tooling Note: This technique requires a small piece of paper of known thickness.

步骤1：从表面上方的刀具开始，关闭主轴。
步骤2：在工具和工件之间放置一张纸（厚度已知）。
Step 3:在来回移动纸张的同时，lower the tool in stepwise increments.
步骤4：Continue lowering the tool until it causes resistance to the sliding piece of paper.
步骤5：将此位置设置为z= the thickness of the paper (e.g.,.003")

提示：练习更多，以便在端铣刀接触到表面时能够轻松识别。.

工具说明：此技术需要一个ER20刀架（31829，来自Tormach工具系统（TTS）和ER20 1/8“夹头（30112，Tormach).

步骤1：Place tool in collet and secure using the setscrew on the side.
步骤2：没有主轴运转，降低工具，直到其刚好位于表面上方。
Step 3:Loosen the setscrew and allow the tool to fall into contact with the workpiece.
步骤4：Tighten the setscrew.
步骤5：将此位置设置为z= 0.

X-Y平面方向

图2。Techniques for aligning the tool in thex–Y飞机。（a）Illustrations of the (i) edgefinder,（ii）芯片，and (iii) paper techniques.(B)工具偏移指南(left)and finding the center of an object(right).

模具备注：
This technique requires an edgefinder (e.g.,#02035186,工业供应理学硕士）。

步骤1：Place edgefinder in collet and start spindle (1000 rpm works well with the edgefinder).
步骤2：使边缘的尖端偏转，使其与初始轴偏心。
Step 3:Starting with thex轴，将边缘朝垂直面移动。封边机的尖端与表面接触后会同心，然后立即回到偏心位置。This sudden "jump" in eccentricity marks the edge.
步骤4：Set the current location to either plus or minus the radius of the tip.参见图。2b有关确定正负偏差的详细信息。

Tooling Note: This technique does not require any specific tooling.

步骤1：从靠近感兴趣面的刀具开始，主轴运行（即。，工具应旋转）。
步骤2：Step the tool towards the surface,until (a) a chip is observed,(b) a mark is made on the surface,or (c) a sound is made from the tool cutting the material.
Step 3:将此位置设置为（加或减）立铣刀半径。

Tip:      This method works best for large diameter endmills.注意，这是一种物理接触方法，会使表面有瑕疵。

Tooling Note: This technique requires a small piece of paper of known thickness.

Step 1：Start with the tool near the face of interest with the spindle running
步骤2：用拇指和食指轻轻地抓着，or by pressing it against the surface place a piece of paper between the tool and the surface.
Step 3:向表面移动工具，直到工具拉动纸张。
步骤4：将此位置设置为（加或减）立铣刀半径和纸张厚度之和。

Tip:                  This method works best for large endmills.
小心：确保手指远离切割工具。

References

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1。Guckenberger DJ,de Groot T万安Beebe DJ,Young EWK,"微加工：塑料微流体器件的超快速成型方法“芯片上的实验室,doi:10.1039/c5lc00234f（2015年）。

2。Guckenberger DJ,de Groot T万安Beebe DJ,Young EWK,"Micromilling Techniques I: Securing Thin Plastic Workpieces for Precise Milling“Chips & Tips（2015）。