4.1 Effects of micro-milling parameters on the surface roughness of the microchannels
In order to study the effects of the micro-milling parameters on the machining outcomes, the orthogonal tests are carried out by different combinations of the spindle speed, feed rate and cutting depth, while the tool inclination angle is set as 5 degrees. Detailed cutting parameters were given in Table 1.
Table 1
The cutting parameters in PMMA inclined Micro-Milling experiment
Tool inclination angle (°) | Spindle speed (r/min) | Feedrate (mm/min) | Depth of cut (mm) |
5 | 4000 | 20 | 0.2 |
6000 | 40 | 0.3 |
8000 | 60 | 0.4 |
The typical surface morphology of the microchannel bottom is measured by the white light interferometer, as shown in Fig. 4. The surface roughness is measured at random positions for each cutting condition, and the measurement results are shown in Table 2. The morphology of the microchannel bottom shown in Fig. 4 (c) is a ripple surface with a certain period, which is mainly consistent with predicted surface shown in Fig. 3. However, there is difference between the machined and predicted surfaces, due to the influence of the runout of the micro-milling tool. The experimental results are analyzed using the simple and practical analysis of extreme variance (ANOVA) to determine the order of influence factors in the orthogonal tests, and to determine the optimal level of each factor in this test, and the results of ANOVA are shown in Table 3.
Table 2
Surface roughness of the machined microchannel bottom
Group | Spindle speed (r/min) | Feedrate (mm/min) | Depth of cut (mm) | Surface roughness Ra(µm) |
1 | 4000 | 20 | 0.2 | 0.103 |
2 | 4000 | 20 | 0.3 | 0.083 |
3 | 4000 | 20 | 0.4 | 0.081 |
4 | 4000 | 40 | 0.2 | 0.102 |
5 | 4000 | 40 | 0.3 | 0.095 |
6 | 4000 | 40 | 0.4 | 0.089 |
7 | 4000 | 60 | 0.2 | 0.188 |
8 | 4000 | 60 | 0.3 | 0.197 |
9 | 4000 | 60 | 0.4 | 0.199 |
10 | 6000 | 20 | 0.2 | 0.041 |
11 | 6000 | 20 | 0.3 | 0.044 |
12 | 6000 | 20 | 0.4 | 0.036 |
13 | 6000 | 40 | 0.2 | 0.047 |
14 | 6000 | 40 | 0.3 | 0.062 |
15 | 6000 | 40 | 0.4 | 0.079 |
16 | 6000 | 60 | 0.2 | 0.113 |
17 | 6000 | 60 | 0.3 | 0.095 |
18 | 6000 | 60 | 0.4 | 0.097 |
19 | 8000 | 20 | 0.2 | 0.078 |
20 | 8000 | 20 | 0.3 | 0.052 |
21 | 8000 | 20 | 0.4 | 0.054 |
22 | 8000 | 40 | 0.2 | 0.041 |
23 | 8000 | 40 | 0.3 | 0.060 |
24 | 8000 | 40 | 0.4 | 0.046 |
25 | 8000 | 60 | 0.2 | 0.077 |
26 | 8000 | 60 | 0.3 | 0.065 |
27 | 8000 | 60 | 0.4 | 0.045 |
Table 3
Results of the analysis of extreme variance
| Spindle speed (r/min) | Feedrate (mm/min) | Depth of cut (mm) |
k1 | 0.126 | 0.064 | 0.088 |
k2 | 0.068 | 0.069 | 0.084 |
K3 | 0.058 | 0.120 | 0.081 |
Extreme variance | 0.068 | 0.056 | 0.007 |
Ranking of influencing factors | Spindle speed > Feedrate > Depth of cut |
Optimal group | Spindle speed 6000r/min, Depth of cut 0.2mm, Feedrate 20mm/min |
According to the results of the extreme variance analysis, it can be found that the spindle speed has the greatest influence on the surface roughness among the cutting parameters, the feed is the second, and the cutting depth has the least influence. The average surface roughness value decreases with the increase of spindle speed, increases with the increase of feed, and decreases with the increase of cutting depth. According to the above experimental results, the spindle speed is the parameter that has the greatest influence on the surface roughness. In order to study the influence of spindle speed and tool inclination on the surface roughness of the bottom of the groove, and then to control the desired surface roughness by adjusting the machining parameters, four typical tool inclination angles and eight spindle speeds are selected in the subsequent micro-milling experimental tests, the feedrate and depth of cut are kept constant. The detailed cutting parameters are shown in Table 4.
Table 4
Single-factor experiment of spindle speed at different inclination angles
Feedrate (mm/min) | 40 |
Depth of cut (mm) | 0.2 |
Spindle inclination angle (°) | Spindle speed (r/min) |
5 | 4000 | 5000 | 6000 | 7000 | 8000 | 9000 | 10000 | 11000 |
10 | 4000 | 5000 | 6000 | 7000 | 8000 | 9000 | 10000 | 11000 |
15 | 4000 | 5000 | 6000 | 7000 | 8000 | 9000 | 10000 | 11000 |
20 | 4000 | 5000 | 6000 | 7000 | 8000 | 9000 | 10000 | 11000 |
From the above experimental tests, the surface roughness of the bottom of the microchannel is obtained when the spindle speed changes from 4000 r/min to 11000 r/min under different inclination angles. The prediction value of the surface roughness can be obtained by extracting the height value of the surface structure through the model established in the Section 2. The surface roughness prediction curve shown in Fig. 5 (a) is obtained by substituting the machining parameters used in the experimental tests shown in Table 4 into the surface prediction model. According to the prediction curve, under the ideal condition, the surface roughness obtained from the model decreases with the increase of the spindle speed, that is, with the increase of the feed per tooth, while the surface roughness increases with the increase of the tilt angle of the spindle, while the change of the surface roughness decreases with the increase of the feed per tooth. The results is obtained from the ideal surface prediction model without considering the influence of spindle runout, machine tool vibration and workpiece material. However, the actual machining situation will be different, and according to the machining condition, when the spindle speed exceeds 8000 r/min, the spindle vibration intensifies, the influence of vibration begins to increase, and the stability of micro-milling becomes worse, thus, the results obtained from the experimental tests at a high speed should have a large difference from the theoretical results. As shown in Fig. 5 (b), the variation of surface roughness with the spindle speed obtained from the experimental tests is given.
From Fig. 5(b), it can be found that the overall trend of surface roughness at the bottom of the microchannel with the spindle speed for four different tool inclination angles is decreasing first and then increasing, and the surface roughness basically reaches the minimum value at 7000–9000 r/min. Comparing with Fig. 5 (a), it can be seen that the change trend before 8000 r/min is basically in line with the results obtained by the prediction model, however, the surface roughness gradually increases after the speed is greater than 8000r/min, which is consistent with the previous discussion. The possible reason is with the increase of the spindle speed, the spindle runout and the overall vibration of the machine intensifies, and the cutting becomes more and more unstable. Moreover, there is no cutting fluid and coolant during the micro-milling process, as the spindle speed increases, the friction and heat between the tool and the workpiece increases, which also leads to a certain impact on the morphology of the machined surface. At the same time, when the spindle speed is too high, the feed per tooth is too small may lead to the cutting layer thickness less than the minimum cutting thickness of the sample material, the PMMA is extruded and scraped but not removed, with the movement of the cutting tool and the material accumulation. When the material accumulation exceeds the minimum cutting thickness, the workpiece material could be removed by the cutting tool. In addition, this instable material removal state will also lead to poor quality of the bottom of the microchannel and the increase of surface roughness.
The variation of the surface roughness with the tool inclination is consistent with the results obtained by the prediction model that the surface roughness increases with the increase of the inclination angle. The difference between the prediction values and that experimental results for the four different inclination angles at low speed are relatively small, and the deviation of the prediction model at 6000 r/min is from 1–12.5%, which shows that the effect of spindle runout and vibration at lower speed is not significant. However, as the spindle speed increases, especially when the speed exceeds 8000 r/min, the effect of tool runout and vibration increases sharply, due to the insufficient rigidity of the machine tool system. Furthermore, as the spindle speed continues to increase, due to the lack of cutting fluid lubrication and coolant, and the melting point of PMMA is relatively low, only 130–140 ℃, the cutting heat will also become one of the important factors affecting the quality of the machined surface, the tool nose cutting the workpiece surface at the extreme speed, and the rapid rise in local temperature may cause the bottom structure of the groove to partially melt, which will also affect the value of surface roughness. When the feed per tooth is too small, the plowing material removal state is also a possible factor of the quality of the machined surface. Based on the experimental results, it is found that the desired surface of the microchannel bottom with different bottom surface roughness can be obtained within a certain range of the cutting parameters.
4.2 Modulation of roughness and wettability of the machined surface
When preparing microfluidic channels, the surface characteristics of microfluidic channels, such as wettability and chemical properties [20], should be taken into account. Wettability is usually evaluated by the contact angle of droplets on its surface [21]. When the contact angle is less than 90°, it is hydrophilic and more than 90 °is hydrophobic. The contact angle on the same material will be affected by the surface characteristics [22–24]. And surface wettability can be influenced by surface roughness, which will affect the flow of liquid in the microfluidic channel [25, 26]. Therefore, the liquid flow state in the microfluidic channel can be controlled by the surface roughness. Based the prediction model and experimental tests, surfaces with different bottom roughness are processed and the contact angles of water droplets are measured using a contact angle measuring instrument (KRUSS DSA100S). The machining parameters are shown in Table 5. The experimental tests measured the contact angle change of another material commonly used for microfluidics, polydimethylsiloxane (PDMS), in addition to the original workpiece material, PMMA, which was used as a mold to replicate the machined surface for measurement. Since PDMS microfluidic chips require oxygen plasma treatment to achieve bonding, the treated PDMS was also tested. The measurement results of the contact angle are shown in Fig. 6 (a).
Table 5
Contact Angle experimental cutting parameters
Group | Feedrate (mm/min) | Spindle speed (r/min) | Spindle inclination angle (°) |
1 | 40 | 4000 | 5 |
2 | 40 | 5000 |
3 | 40 | 6000 |
4 | 40 | 7000 |
5 | 40 | 8000 |
6 | 40 | 4000 | 20 |
7 | 60 | 4000 |
8 | 80 | 4000 |
9 | 100 | 4000 |
10 | 140 | 4000 |
11 | 180 | 4000 |
According to the experimental results, PDMS changed from hydrophobic to hydrophilic after oxygen plasma treatment, and the variation of water contact angle on different roughness surfaces on PDMS before and after the treatment showed an overall increase with the increase of roughness. The effect of different roughness surfaces, including PMMA, PDMS and PDMS after oxygen plasma treatment, on water contact angle is the same, and the contact angle mainly increases with the increase of surface roughness. For the explanation of contact angle on the rough surfaces, Wenzel model and Cassie-Baxter model are the most representative wetting models. According to the Wenzel model, an increase in surface roughness leads to an increase in the contact angle of hydrophobic surfaces and a decrease in the contact angle of hydrophilic surfaces. On the contrary, according to the Cassie-Baxter model, an increase in air pocket caused by the increase in surface roughness below the droplet leads to an increase in contact angle, regardless of whether the surface is hydrophobic or hydrophilic. According to the measured results, the variation of the contact angle is consistent with the prediction of the Cassie-Baxter model, where air pockets may form within the regularly undulating structure of the bottom surface due to the bottom structure formed by the inclined micro-milling process. In addition, according to the equations of the model, as the roughness increases, the depth and period of the bottom structure increases, leading to a decrease in the contact area fraction between the liquid and the solid, which results in the contact angle increases. With the increase in contact angle, the flow of liquid in the microchannel will also be affected. From the general rule of capillary phenomenon is known, when the contact angle is larger, it is more difficult for the liquid to enter the capillary. Thus, it can be presumed that the liquid flow in the microchannel will also be impeded with the increase in contact angle. From the above experimental tests, it can be found that the wettability of these three surfaces can be changed by different surface roughness, thus, the microfluidic chip with different bottom roughness of the microchannel can be processed to realize the flow control of the microfluidic channel.
The above method of inclined micro-milling to control the roughness at the bottom of the groove can be applied to prepare microfluidic channels to achieve control of fluid flow in microfluidic channels. Wu et al. reported that the flow friction in silicon microchannels increases with increasing the surface roughness. The lower the value of surface roughness, the lower the flow friction. Based on this, a better control of the channel bottom roughness by inclined micro-milling, a larger flow pressure is required to pass through the microchannel with a larger flow friction. Therefore, the flow path can be controlled by changing the surface roughness at the bottom of the mirochannel. Three channels with different bottom roughness were processed to achieve selective fluid flow. The bottom surface roughness of the smooth channel was 0.0384 µm, the bottom surface roughness of the rougher channel was 0.156 µm, and the bottom surface roughness of the roughest channel was 0.351 µm, and fluid flow experiments were conducted to control the pressure by changing the flow rate. The experimental results are shown in Fig. 7.
When the liquid speed of 5 µL/min, only the middle smooth channel liquid circulation When the flow rate increases to 20 µL/min, the upper rougher channel liquid circulation. While, when the flow rate of more than 50 µL/min, the three channels are circulating. The experimental results show that the order of circulation of the three channels and through to the bottom surface roughness, the smoother the bottom, the smaller the water contact angle, the easier it is for red ink to go through the channel and become the lead in circulation. The rougher the surface, the greater the through-liquid pressure required for circulation. According to the experimental results, microchannels machined by inclined micro-milling can be used to prepare the microfluidic chips with controllable circulation order of the microchannels.