A generalized dynamic model for spindle vibration influencing surface topography in different ultra-precision machining processes

Dong, Zhili; Zhang, Shaojian; Zhang, Xiong; Rao, Xixin

doi:10.1007/s00170-018-1814-3

Cited by 13 publications

(4 citation statements)

References 20 publications

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“…In view of the above disadvantages, recent investigations on the vibration in diamond turning are performed on the multi-direction and multi-frequency conditions. For instance, Zhang et al proposed a five-degree-of-freedom dynamic model for the aerostatic bearing spindle to explore the mechanism of multi-direction vibration (in the x -, y - and z -direction) and its influence on surface topography in diamond turning [80,81]. Their studies show that on the general effect of the axial and radial vibrations, a spiral and two-fold patterns surface profile generates on the machined surface.…”

Section: Theoretical Modelsmentioning

confidence: 99%

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Zong

2019

Micromachines

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In this work, the influencing factors and corresponding theoretical models for the surface topography in diamond turning process are reviewed. The surface profile on one tool feed is the elementary unit of surface topography. The influences coupled with the models of the duplication effect of the tool edge profile, material spring back, and plastic side flow are outlined in this part. In light of the surface profile on one tool feed and “trim principle”, the modeling methods of surface topography along the radial direction (2D surface topography) are commented. Moreover, the influence of the vibration between the diamond tool and workpiece on the 2D surface topography is discussed, and the theoretical models are summarized. Finally, the issues for modeling of 3D surface topography, particularly the influences of material defects, are analyzed. According to the state-of-the-art surface topography model of the diamond turned component, future work in this field is therefore predicted.

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Section: Theoretical Modelsmentioning

confidence: 99%

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Zong

2019

Micromachines

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“…It can generate surfaces with a very high form accuracy as well as single digit nanometric surface roughnesses. The price and availability of these machines has drastically improved [ 16 , 17 , 18 , 19 , 20 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Analysis of Ductile Cutting Regime in Face Milling of Sintered Silicon Carbide

et al. 2022

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In this study, sintered silicon carbide is machined on a high-precision milling machine with a high-speed spindle, closed-loop linear drives and friction-free micro gap hydrostatics. A series of experiments was undertaken varying the relevant process parameters such as feedrate, cutting speed and chip thickness. For this, the milled surfaces are characterized in a process via an acoustic emission sensor. The milled surfaces were analyzed via confocal laser scanning microscopy and the ISO 25178 areal surface quality parameters such as Sa, Sq and Smr are determined. Moreover, scanning electron microscopy was used to qualitatively characterize the surfaces, but also to identify sub-surface damages such as grooves, breakouts and pitting. Raman laser spectroscopy is used to identify possible amorphization and changes to crystal structure. We used grazing incidence XRD to analyze the crystallographic structure and scanning acoustic microscopy to analyze sub-surface damages. A polycrystalline diamond tool was able to produce superior surfaces compared to diamond grinding with an areal surface roughness Sa of below 100 nm in a very competitive time frame. The finished surface exhibits a high gloss and reflectance. It can be seen that chip thickness and cutting speed have a major influence on the resulting surface quality. The undamaged surface in combination with a small median chip thickness is indicative of a ductile cutting regime.

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“…Omar et al [ 16 ] mentioned a general and modified model that combines the effects of tool runout, tool deflection, system dynamics, flank wear and tool tilt on surface roughness. Dong et al [ 17 ] developed a generalized kinetic model to study the vibration of the spindle and its effect on surface formation in different UPM processes. Huo et al [ 18 ] established a modified cutting force model and sidewall surface generation model, which considers the effect of tool deflection on cutting force and surface generation.…”

Section: Introductionmentioning

confidence: 99%

Effect of KDP-Crystal Material Properties on Surface Morphology in Ultra-Precision Fly Cutting

Chen

Fan

2020

Micromachines

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To study the effect of material properties on the surface morphology of potassium dihydrogen phosphate (KDP) crystals, an ultra-precision fly cutting machine tool with a single-point diamond tool was used to perform a cutting experiment on (100) crystal plane of the KDP crystal. The elastic modulus, shear modulus, hardness, and dislocation of KDP crystals are taken into the cutting force model by introducing the strain gradient plasticity theory. Since the size effect and dynamic response will affect the surface roughness during ultra-precision machining, the surface roughness of workpieces in ultra-precision fly cutting is hard to predict. Based on the previously established strain gradient plasticity theoretical model, cutting force model, and the dynamic characteristics of the ultra-precision fly cutting system, a surface morphology prediction model under the influence of KDP crystal material properties was established. Finally, the accuracy of the surface morphology prediction model was verified by ultra-precision fly cutting experiments, and identified the frequency range of the characteristic signal caused by the anisotropy of the KDP crystal from the frequency, thereby verifying the KDP crystal material properties has a significant effect on the surface of the machined workpiece roughness.

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A generalized dynamic model for spindle vibration influencing surface topography in different ultra-precision machining processes

Cited by 13 publications

References 20 publications

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Experimental Analysis of Ductile Cutting Regime in Face Milling of Sintered Silicon Carbide

Effect of KDP-Crystal Material Properties on Surface Morphology in Ultra-Precision Fly Cutting

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