Decoration of metal surface by dimples using ball-end milling process

Structured surfaces are often employed to enhance physical properties of metal products. Dimples are usually generated on metal surface by a ball-end milling with a combination of tool movements in horizontal and vertical directions. It is important to note that only horizontal tool movements of ball-end milling with high feed rate can also generate the dimpled surface. Authors already proposed a technique to generate desired dimple shape on the metal surfaces using a machining center. Following the technique, decorating process of the metal surface has been achieved. In the generation processes deformation of the dimples is observed. The deformation of the dimples is considered using numerical model and the mechanism to cause the deformation is analyzed. In the experiment decorations are successfully achieved with various shapes of dimples on a metal surface by using a sub-millimeter ball-end mill.