Determining issues in optimal turning of micro-structured functional surfaces

Zhang, Xu; Liu, Qiang; Zhou, Xiaoqin; Lin, Chao

doi:10.1007/s00170-015-7163-6

Cited by 7 publications

(8 citation statements)

References 16 publications

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“…2. The tilted surface is first cut with spindle speed of 120 r/min and x-axis direction feedrate of 10 μm/r, and the toolpath is detailed in author's another paper [13].…”

Section: Analyze Of Experimental Resultsmentioning

confidence: 99%

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In situ measurement and error compensation of optical freeform surfaces based on a two DOF fast tool servo

Liu

Pan

Yan

et al. 2015

Int J Adv Manuf Technol

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Freeform optics are widely used in many fields with its excellent optical performances. Fast tool servo (FTS) diamond turning technology are considered to be very promising technique for freeform surface fabrication. However, some elements may influence the machining accuracy, such as the spindle speed drift, periodical change cutting force, and diamond turning machine (DTM) motion errors. In this paper, an in situ measurement method and an error compensation machining technique are proposed to improve FTS technique machining accuracy. The machined surface profile data is obtained by a linear variable differential transformer (LVDT) and the error compensation machine is implemented by a two degree of freedom (DOF) FTS. The experiment results show that the form error is dropped by 20 % and surface roughness of 18.1 %. This technology is easy to take out that contributes to the application of high precision freeform surfaces in aerospace, military, biochemical medical, communication, and many other fields.

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“…2. The tilted surface is first cut with spindle speed of 120 r/min and x-axis direction feedrate of 10 μm/r, and the toolpath is detailed in author's another paper [13].…”

Section: Analyze Of Experimental Resultsmentioning

confidence: 99%

“…(1) Freeform optics is first machined by the two DOF FTS system [13,14]. (2) Machined surfaces profile is measured on-machine by a pneumatic light touch LVTD assisted with x-axis slide feedrate and spindle rotation of DTM, and LVDT tiny contact force can prevent the probe scratching the measured surface.…”

Section: Introductionmentioning

confidence: 99%

In situ measurement and error compensation of optical freeform surfaces based on a two DOF fast tool servo

Liu

Pan

Yan

et al. 2015

Int J Adv Manuf Technol

Self Cite

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“…According to Zhang’s article [ 19 ], we divided the vibration between the tool–workpiece into two directions, the Z -direction and the Y -direction

where m is the respective effective mass, c n ( n = z,y ) is the respective damping coefficients, k n ( n = z,y ) is the respective stiffness, and F n ( n = z,y ) is the respective dynamic cutting force.…”

Section: Dynamic Cutting Force Modellingmentioning

confidence: 99%

“…As the shear angle is determined, accordingly, the position of the shear face can be determined. The shear strain on the shear face is influenced by the magnitude of each component of the slip velocity of the shear face so that the expression for the shear strain on the shear surface is obtained as

where

is the shear surface movement velocity, whose direction is parallel to the shear surface [ 19 ], and the expression is

where

is the velocity perpendicular to the shear plane and expressed as

…”

Section: Dynamic Cutting Force Modellingmentioning

confidence: 99%

Research on the Method of Reducing Dynamic Cutting Force in Aspheric Machining

2023

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With the rapid development of photoelectric communication and other fields, the demand for high-precision aspheric mirrors has been increasing. Predicting dynamic cutting forces is vital in selecting machining parameters and also affects the surface quality of the machined surface. This study comprehensively considers the effects of different cutting parameters and workpiece shape parameters on dynamic cutting force. The actual width of cut, depth of cut, and shear angle are modelled while considering the effects of vibration. A dynamic cutting-force model considering the aforementioned factors is then established. Using experimental results, the model accurately predicts the average value of dynamic cutting force under different parameters and the range of fluctuation of dynamic cutting force, with a controlled relative error of about 15%. The influence of workpiece shape and workpiece radial size on dynamic cutting force is also considered. The experimental results show that the greater the surface slope, the more dramatic the dynamic cutting force fluctuations. This lays the foundation for subsequent writing on vibration suppression interpolation algorithms. The influence of the radius of the tool tip on dynamic cutting forces leads to the conclusion that to achieve the goal of reducing the fluctuation of cutting forces, diamond tools with different parameters should be selected for different feed rates. Finally, a new interpolation-point planning algorithm is used to optimize the position of interpolation points in the machining process. This proves the reliability and practicability of the optimization algorithm. The results of this study are of great significance to the processing of high-reflectivity spherical/aspheric surfaces.

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“…The input-output relationships put forward in the papers mentioned above refer to single-pass machining and highlight the connection between the machined surface roughness and the cutting parameters, including the depth of cut. These input-output relationships are extremely important for the optimization of the cutting parameters, an aspect often ignored [43]. A further interesting paper, [20], discusses the issue of distributing the total depth of cut into several passes (multi-pass turning) for the machining of slender rods.…”

Section: Literature Reviewmentioning

confidence: 99%

A new method for establishing the depths of cut for cast iron parts turning

Ivan

Gavrus

Oancea

2018

J Braz. Soc. Mech. Sci. Eng.

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It is well known that determining the machining parameters is an important issue of process planning. Machining parameters have a significant influence on the cost and productivity of different machining processes. Among these parameters, special attention comes to the depth of cut. In this respect, the present paper proposes a new method for establishing the depths of cut related to technological sequences-roughing, semi-finishing and finishing-such as to gradually eliminate the errors that occur during surface machining in order to ensure the required accuracy. Hence, depths of cut that are greater than necessary are avoided, thus facilitating certain economic advantages. The operating mechanism underlying the discussed method is based on analysing the roughness of the surface to be machined. Materialization of the method based on the CAPP components is a software tool conceived in Delphi environment and consists of two modules: one for determining the technological sequences and the other one for determining the depths of cut required by the technological sequences. The method also allows the determination of the billet dimensions and of the related tolerances of the analysed surfaces. The software tool includes a database built upon a set of mathematical models for appraising the flaws to be eliminated by removal of the material layer. The paper addresses the turning of cast iron parts and provides a solution for multi-pass turning as well as a case study for exemplification purposes. Keywords Cast iron parts machining • Depth of cut • Machined surface roughness • Cutting sequences • Software tool Abbreviations a(3,15), name(3) Matrices of the database cab Billet casting process accuracy grade Df Clamping surface diameter (mm) Dm Maximum part dimension (mm) Dn cib , fin cib

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Determining issues in optimal turning of micro-structured functional surfaces

Cited by 7 publications

References 16 publications

In situ measurement and error compensation of optical freeform surfaces based on a two DOF fast tool servo

In situ measurement and error compensation of optical freeform surfaces based on a two DOF fast tool servo

Research on the Method of Reducing Dynamic Cutting Force in Aspheric Machining

A new method for establishing the depths of cut for cast iron parts turning

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