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

He, Chao; Zong, Wenjun

doi:10.3390/mi10050288

Cited by 20 publications

(9 citation statements)

References 124 publications

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“…Its formation is dependent on the mechanical properties of the material, primarily the strength and ductility. While models that take into consideration the elastic recovery, chip thickness and swelling ratio have been formulated, most are still based on assumptions and not followed by experimental observations [67], [70]. Nonetheless, a mathematical model developed by Liu.…”

Section: Figurementioning

confidence: 99%

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Micallef

Zhuk²,

Aria

2020

Coatings

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Owing to their high hardness, fracture toughness and oxidation resistance, tungsten carbide (WC) coatings are extensively deposited on parts that operate in demanding applications, necessitating wear, erosion, and corrosion resistance. The application of thick and hard WC coatings has an inevitable effect on the original dimensions of the parts, affecting the geometrical tolerances and surface roughness. The capability of achieving a sub-micron surface finish and adhere to tight geometrical tolerances accurately and repeatably is an important requirement, particularly with components that operate in high-precision sliding motion. Meeting such requirements through conventional surface finishing methods, however, can be challenging due to the superior mechanical and tribological properties of WC coatings. A brief review into the synthesis techniques of cemented and binderless WC coatings is presented together with a comprehensive review into the available techniques which are used to surface finish WC-based coatings with reference to their fundamental mechanisms and capabilities to process parts with intricate and internal features. The binderless WC/W coating considered in this work is deposited through chemical vapour deposition (CVD) and unlike traditional cemented carbide coatings, it has a homogenous coating structure. This distinctive characteristic has the potential of eliminating key issues commonly encountered with machining and finishing of WC-based coatings. Here, six contact and non-contact surface finishing techniques, include diamond turning, precision grinding, superfinishing, vibratory polishing, electrical discharge machining, and electropolishing are discussed along with their current use in industry and limitations. Key challenges in the field are highlighted and potential directions for future investigation, particularly on binderless WC coatings, are proposed herein.

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Section: Figurementioning

confidence: 99%

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Micallef

Zhuk²,

Aria

2020

Coatings

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“…Recently, there has been a dramatic increase in the breadth of applications for ultraprecision machining using single-crystal diamond tools [6]-particularly in the fields of manufacturing optical or magnetic parts, such as magnetic discs, polygonal mirrors, copier drums, and different lens shapes. As a result, the technique has successfully been expanded to machining various soft materials, creating mirror-like surfaces with submicrometer geometrical precision using ultraprecision machining and a single-crystal diamond tool [7].…”

Section: Introductionmentioning

confidence: 99%

“…Previous research indicates that surface quality from diamond turning is influenced by many factors such as machine vibration, chatter, tool wear, tool geometry, built-up edge, chip striking, and lubrication. Indeed, the surface roughness of the diamond turning machine parts plays a crucial role [6,7]. ere are several difficulties when studying the surface roughness of diamond turning parts.…”

Section: Introductionmentioning

confidence: 99%

Applying Bayesian Optimization for Machine Learning Models in Predicting the Surface Roughness in Single-Point Diamond Turning Polycarbonate

Nguyen

Truong

et al. 2021

Mathematical Problems in Engineering

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This paper deals with the prediction of surface roughness in manufacturing polycarbonate (PC) by applying Bayesian optimization for machine learning models. The input variables of ultraprecision turning—namely, feed rate, depth of cut, spindle speed, and vibration of the X-, Y-, and Z-axis—are the main factors affecting surface quality. In this research, six machine learning- (ML-) based models—artificial neural network (ANN), Cat Boost Regression (CAT), Support Vector Machine (SVR), Gradient Boosting Regression (GBR), Decision Tree Regression (DTR), and Extreme Gradient Boosting Regression (XGB)—were applied to predict the surface roughness (Ra). The predictive performance of the baseline models was quantitatively assessed through error metrics: root means square error (RMSE), mean absolute error (MAE), and coefficient of determination (R2). The overall results indicate that the XGB and CAT models predict Ra with the greatest accuracy. In improving baseline models such as XGB and CAT, the Bayesian optimization (BO) is next used to determine their best hyperparameters, and the results indicate that XGB is the best model according to the evaluation metrics. Results have shown that the performance of the models has been improved significantly with BO. For example, the values of RMSE and MAE of XGB have decreased from 0.0076 to 0.0047 and from 0.0063 to 0.0027, respectively, for the training dataset. Using the testing dataset, the values of RMSE and MAE of XGB have decreased from 0.4033 to 0.2512 and from 0.2845 to 0.2225, respectively. Moreover, the vibrations of the X, Y, and Z axes and feed rate are the most significant feature in predicting the results, which is in high accordance with the literature. We find that, in a specified value domain, the vibration of the axes has a greater influence on the surface quality than does the cutting condition.

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“…He and Zong 16 described the mechanism of multi-frequency vibration on the optical performance of diamond-turned workpieces, and he used well-established two-step process technology to reduce the effect of vibration, which was experimentally proved to be highly effective. 17,18 Gao et al 19 investigated the relationship between the ripple errors of machined surfaces and oil source pressure fluctuations and demonstrated that an unsteady oil source pressure had a remarkable effect on the topography of a workpiece. Wei et al 20 theoretically and experimentally investigated the dynamic characteristics of air spindles and their effect on medium-frequency ripples in machined surface shapes.…”

Section: Introductionmentioning

confidence: 99%

Analysis of characteristics of arc shape caused by intermittent cutting force and dynamic vibration in ultra-precision cutting processes

Wei

Chen

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article analyzes the phenomenon of “arc shape” in surface characteristics caused by dynamic vibration in ultra-precision machining. First, a surface simulation model is proposed based on the effect of the tool shape on the cutting profile. The accurate mapping relationship between spindle speed, feed speed, relative vibration, and the motion track of the tool tip to the workpiece profile is also established. Thereafter, the input frequency spectrum signature of an intermittent cutting force is found to be determined by the spindle speed and workpiece characteristics, and this is verified by experimental results. A phased, self-regulated mode of forced vibration caused by intermittent cutting force is then proposed, and the forming of the arc shape feature is explained. In addition, it is revealed that output vibration can be kept at a low level by adjusting the spectrum curve of the input signal.

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

Cited by 20 publications

References 124 publications

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Applying Bayesian Optimization for Machine Learning Models in Predicting the Surface Roughness in Single-Point Diamond Turning Polycarbonate

Analysis of characteristics of arc shape caused by intermittent cutting force and dynamic vibration in ultra-precision cutting processes

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