Surface micro-structuring of TC6 alloy by diamond grit tool

In response to the escalating demand for functional surfaces in marine applications and aerospace, this study investigates the precision fabrication of microstructured surfaces on TC6 using structured diamond grit tools. A novel kinematic model is developed to reveal the formation mechanisms of microstructures, integrating numerical simulations and experimental validation to optimize critical cutting parameters. The simulations reveal that increasing the tool-workpiece speed ratio enhances periodicity and reduces the overlapping effects of microstructures. Controlled feed speeds (20–100 rpm) ensure uniform separation distances between microstructures. Experimental results demonstrate that the distribution of microstructures is determined by the interplay between speed ratio ( v s / v w ) and feed speed ( f ). And their topographies are dominated by the dynamic morphology of the diamond grit. Notably, the proposed methodology contributed to the fabrication of microstructured arrays with controlled depths (7–15 μm) and good consistency. This work deepens the understanding of the distribution of microstructures and provides a scalable solution for fabricating arrayed structured surfaces.