The workpiece is a test piece and the material is plexiglass. The structure is shown in Figure 1.
Figure 1 Test piece structure
The specific requirements of the groove width W1, the groove pitch W2, the number of grooves n, and the groove range W are as shown in Table 1.
Table 1 Test parts processing requirements 
Since W1 is only 0.1 mm, and the number of fine grooves processed on the same workpiece is large, the consistency of the groove is required, and the material is plexiglass, which has no conductivity, and thus processing is difficult, and research is required.
Process analysis
Existing tools cannot meet the requirements of a width of 0.1 mm in size, which limits the application of machining methods such as milling. However, due to the small hardness of the plexiglass, according to the specific conditions of the workshop, the tool grinding machine is modified, and the cutting method is used to complete the processing. The tool is guaranteed by a tool sharpening.
2. Tool design
Since the width of the groove is 0.1 mm, the width d of the cutter is designed to be 0.095 mm. At this time, the strength of the tool is very weak, so when designing the tool, in the case of ensuring the strength, the front angle is maximized and the sharpness of the tool is enhanced. Also consider the influence of the tool's main back angle and the secondary back angle on the machining.
Based on the above principles, the front angle of the design tool is 12°, the main rear angle is 8°, the secondary rear angle is 0.2°, and the effective depth of the tool is 0.85 mm. Further consideration is made not to affect the machined groove, and the tool depth direction is designed. An angle of 0.3° avoids the effect on the machined part. In order to increase the rigidity of the tool, a smooth transition of the arc is designed. Taking into account factors such as the installation of the tool, the final design of the tool is shown in Figure 2.
Figure 2 Micro-groove cutter
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