Fabrication of continuous slim aluminum fibers using a multi-tooth tool

In this paper, we describe the development of a multi-tooth tool to fabricate continuous, slim aluminum fibers of an equivalent diameter of under 100 µm. Following an analysis of the process of the fabrication of aluminum fibers, we designed a geometric cutting model of the multi-tooth tool with a large inclination as well as the mechanism to form continuous, slim aluminum fibers. We conducted experiments to determine the influence of process parameters on the surface topography and the equivalent diameter of the aluminum fiber. We obtained the continuous, slim aluminum fibers with a micro-fin structure when the cutting speed, cutting depth, and feed rate were in the ranges of 0.08–0.18 mm, 5–15 m/min, and 0.1–0.2 mm/r, respectively. We found that the equivalent diameter of the aluminum fiber gradually increased with decreasing cutting speed, and increasing feed rate and cutting depth. Moreover, the result of a composition analysis indicated that the generated cutting heat had a minimal effect on the oxidation of the aluminum fiber.