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

Abstract

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.