Ultra-Precision Machining of a Large Amplitude Sinusoidal Ring Surface Based on a Slow Tool Servo

Ji, Shijun; Yu, Huijuan; Zhao, Jun; Liu, Xiaolong; Zhao, Ming

doi:10.5545/sv-jme.2015.2528

Cited by 9 publications

(4 citation statements)

References 20 publications

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“…The selection of tool radius and wrap angle can be determined by analyzing the stretch-out view Fig. 15 of umbrella surface [19]. Points P i and P k are the actual cutting points on the curve, l r , r i , i and r k , k are the radius of curvature and arc angle at points P i and P k , respectively.…”

Section: Parameters Selection Of Cutting Toolmentioning

confidence: 99%

Ultra-precision machining of a large amplitude umbrella surface based on slow tool servo

Ning

Zhao

et al. 2020

Int. J. Precis. Eng. Manuf.

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Due to its excellent optical performance and system integration property, micro-nano structure function surface has been widely used in optical apparatus and energy collection equipment. But using traditional processing method can't obtain a mirror-like surface with high form accuracy and low roughness for sake of its complex micro-nano structure. In this paper, a large amplitude umbrella surface is special designed and single point diamond turning (SPDT) technology based on slow tool servo (STS) is used for umbrella surface machining. The tool path generation, tool radius compensation and tool geometry optimization are detailed for fabricating the desired surface. A new method combined with constant angle and analytical mathematical optimization is proposed for tool path optimization. A large amplitude umbrella surface with the maximum amplitude 0.2 mm and period 8 per cycle is designed, and the machining experiment is carried out on Nanoform 250 ultra-precision machine tool. From the form accuracy 1 μm in surface residual error and 279.12 nm in RMS and the surface roughness 230.10 nm in Ra for the machined surface, it can be seen that a large amplitude umbrella surface is easily fabricated by SPDT under STS controlling. Keywords Large amplitude umbrella surface • Slow tool servo (STS) • Analytical optimization method • Ultra-precision machining • Single point diamond turning (SPDT)

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Section: Parameters Selection Of Cutting Toolmentioning

confidence: 99%

Ultra-precision machining of a large amplitude umbrella surface based on slow tool servo

Ning

Zhao

et al. 2020

Int. J. Precis. Eng. Manuf.

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“…Aluminium alloy is frequently used work material for diamond turn machining (DTM) due to its machinability, 1, 2 and low density of this material finds its suitability as metallic mirrors in space-borne applications. 3 This type of mirror needs to maintain form accuracy and surface roughness, 4 and this is why DTM-machined aluminium alloy is capable to cater the requirements of space-borne applications.…”

Section: Introductionmentioning

confidence: 99%

Improvement in surface quality of diamond-turned aluminium substrate by using hydrogen peroxide: a molecular dynamics simulation study

Ranjan

Sharma

Balasubramaniam

2020

Journal of Micromanufacturing

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In this work, the atomic mechanism of chemical treatment on diamond-turned aluminium surface due to aqueous H2O2 is investigated using a reactive molecular dynamics simulation (R-MDS). This study is carried out to understand the mechanism of surface quality improvement of a diamond-turned aluminium workpiece due to chemical treatment. Surface quality improvement is focused to analyse the effect of chemical treatment process for improving surface finish, reflectance and chemical stability of the workpiece. It is observed that the diamond-turned surface contains a higher cohesive energy as compared to atomically smooth surfaces. Chemical treatment does more material removal on nano-peaks with respect to the smooth surface, and this helps to reduce the cohesive energy as low as naturally possible. By applying this treatment, the optical quality of the workpiece gets enhanced drastically. R-MDS also reveals that the nano-peaks of diamond turn machining (DTM) surface can further improve surface finish by using the chemical treatment process, and the same is validated by experiments. Experimental data also support that due to the reduction of surface roughness, reflectance increases in a broad band of wavelength. The present work shows that material removal from the nano-peaks of workpiece occurs due to the oxygen radicals generated from H2O2, which raise the local temperature, followed by temperature-assisted chemical reaction. When most of the nano-peak atoms are removed, further material removal stops. Experimental results also support the mechanism of such process of chemical treatment. Hence, the diamond turned surface can be further improved beyond the capability of the diamond turning process to cater the need for optics and astronomical mirror at-least one step ahead in the domain of ultra-precision manufacturing.

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“…Shijun Ji et al fabricated a large amplitude sinusoidal ring surface that was based on STS, the kinematic characteristic of machine axes is analyzed to assess the feasibility of the fabrication process. The tool path generation, tool geometry optimization, and tool radius compensation are also investigated for the fabrication of the sinusoidal ring surface, an experimental sample with 0.4 mm amplitude sinusoidal ring surface is successfully machined, and a form accuracy 0.247 μm in PV and surface roughness 7.5 nm in Ra is obtained [ 14 ]. Szymon Wojciechowski et al proposed a method to minimize the cutting forces and vibration during ball end milling.…”

Section: Introductionmentioning

confidence: 99%

Ultra-Precision Machining of a Compound Sinusoidal Grid Surface Based on Slow Tool Servo

Zhao

et al. 2018

Materials

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Compound sinusoidal grid surface with nanometric finish plays a significant role in modern systems and precision calibrator, which can make the systems smaller, the system structure more simple, reduce the cost, and promote the performance of the systems, but it is difficult to design and fabricate by traditional methods. In this paper, a compound freeform surface constructed by a paraboloidal base surface and sinusoidal grid feature surface is designed and machined by slow tool servo (STS) assisted with single point diamond turning (SPDT). A novel combination of the constant angle and constant arc-length method is presented to optimize the cutting tool path. The machining error prediction model is analyzed for fabricating the compound sinusoidal grid surface. A compound sinusoidal grid surface with 0.03 mm amplitude and period of 4 is designed and cutting process is simulated by use of MATLAB software, machining experiment is done on ultra-precision machine tool, the surface profile and topography are measured by Taylor Hobson and Keyence VR-3200, respectively. After dealing with the measurement data of compound freeform surface, form accuracy 4.25 μm in Peak Village value (PV), and surface roughness 89 nm in Ra are obtained for the machined surface. From the theoretical analysis and experimental results, it can be seen that the proposed method is a reasonable choice for fabricating the compound sinusoidal grid surface.

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Ultra-Precision Machining of a Large Amplitude Sinusoidal Ring Surface Based on a Slow Tool Servo

Cited by 9 publications

References 20 publications

Ultra-precision machining of a large amplitude umbrella surface based on slow tool servo

Ultra-precision machining of a large amplitude umbrella surface based on slow tool servo

Improvement in surface quality of diamond-turned aluminium substrate by using hydrogen peroxide: a molecular dynamics simulation study

Ultra-Precision Machining of a Compound Sinusoidal Grid Surface Based on Slow Tool Servo

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