A theoretical and experimental investigation of orthogonal slow tool servo machining of wavy microstructured patterns on precision rollers

The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was proposed * Corresponding Author.

Section: Introductionmentioning

confidence: 99%

Study of the tool path generation method for an ultra-precision spherical complex surface based on a five-axis machine tool

Xing

Zhao

Cui

et al. 2021

“…Mak C. H. et al [6] studied the effect of single point diamond turning on the machining accuracy of the V-shaped groove on the high-precision drum surface using different processing strategies, and they optimized the processing parameters including the turning depth and the turning times. Kong L. B. et al [7] used single-point diamond turning with orthogonal slow-tool servo technology to process the corrugated micro-structure on the high-precision cylindrical surface under the 9 sets of different processing parameters. Mukaida M. et al [8] used slow-tool servo diamond turning technology to process micro-lens array on single silicon material, and they studied the machining form error, surface morphology and turning force experimentally.…”

Section: Introductionmentioning

confidence: 99%

Theoretical modeling and machining experiments of cylindrical microstructure assisted by single-point diamond turning

Zhao

et al. 2021

Micro structure requires nanometer-scale surface roughness and micro-or even sub-micron form error accuracy in different applications. Two kinds of modeling theories and methods of micro-feature of rotating body and non-rotating body are studied, and the corresponding tool turning trajectory planning method is put forward. In order to process the designed micro-feature structure successfully and avoid the interference and overcutting between tool and workpiece caused by improper selection of tool parameters, the cutting parameters are analyzed and two error theories are proposed. Then a precision driven turning trajectory planning method is proposed, which can optimize the turning parameters according to the setting error and then optimize the trajectory. The experiments are carried out to verify the proposed theory. The surface roughness and surface accuracy of the features were measured by Talysurf PGI 1240 and KEYENCE vhx900 respectively. The surface roughness and surface accuracy of the cylindrical sine wave groove micro feature surface are 0.1714μm and 1.32μm respectively. The surface roughness and surface accuracy of the cylindrical sinusoidal mesh micro feature surface are 0.1625μm and 1.8μm respectively. The results meet expectations and verify the reliability of the error theory and the trajectory optimization theory.

“…The accuracy of the machined surface was difficult to ensure without precise synchronization of the two motions. Kong et al [23] machined a wavy microstructured pattern on precision rollers using a single point diamond turning machine. Two-dimensional sinusoidal patterns with wavy cycles were machined on the roller with the proposed method.…”

Section: Introductionmentioning

confidence: 99%

Diamond machining of freeform-patterned surfaces on precision rollers

Liu

Cheung

Feng

et al. 2019

Rapid development of freeform surfaces faces the challenges of not only higher form accuracy and smoother surface finishing, but also high machining efficiency and lower manufacturing cost. Combining diamond turning and roll-toroll embossing technologies is a promising solution to fulfil these requirements. This paper presents a generic method to design and machine freeform surfaces on precision rollers. The freeform surface designed on the flat substrate is first transferred onto the cylindrical roller surface. The freeform-patterned roller surface is then diamond turned using the toolpath generated by a purposely developed toolpath generator. With the proposed method, the complex freeform surfaces designed on flat substrate can be transferred to and precisely machined on the cylindrical roller surfaces. A cutting experiment has been conducted to demonstrate the capability of the proposed method. In the experiment, a sinusoidal surface was designed and diamond turned on a precision roller. The results demonstrate that the proposed method is accurate and effective. The proposed method provides guidance for the design and precision manufacturing of freeform-patterned surfaces on precision rollers.