Theoretical and experimental investigation of the effect of the machining process chain on surface generation in ultra-precision fly cutting

2018 ◽  
Vol 99 (9-12) ◽  
pp. 2819-2831 ◽  
Author(s):  
Chenyang Zhao ◽  
Chi Fai Cheung
Keyword(s):  
Experimental Investigation ◽  
Machining Process ◽  
Surface Generation ◽  
Process Chain ◽  
Fly Cutting ◽  
Ultra Precision

scholarly journals A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

2018 ◽  
Vol 10 (1) ◽  
pp. 168781401774714
Author(s):  
Dongju Chen ◽  
Xianxian Cui ◽  
Ri Pan ◽  
Jinwei Fan ◽  
Chenhui An
Keyword(s):  
Prediction Model ◽  
Surface Topography ◽  
Rotation Speed ◽  
Surface Generation ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Spindle System ◽  
Fly Cutting ◽  
Ultra Precision ◽  
Aerostatic Spindle

In ultra-precision fly-cutting machining, the aerostatic spindle is the key component, which has significant influence on the machined surface quality. The unbalanced spindle directly affects the machining accuracy. In this article, a prediction model of machining surface topography is proposed which involves the effect of the gas film performance of spindle in microscale. With the Weierstrass function, unstable transient response of the aerostatic spindle system is derived by the motion model of the spindle, which response signal represents the surface profile in the ultra-precision machining. Meanwhile, the experiment is performed with different rotation speed of the spindle. And the effect of the unbalanced aerostatic spindle on the surface generation is discussed in time and frequency domain. The conclusion shows that the similar cyclical surface ripple of the workpiece is independent of the spindle speed, and the rotation speed of the spindle and unbalanced spindle directly affects the machining surface topography. This study is quite meaningful for deeply understanding the influence rule of spindle unbalanced error from the viewpoint of machined surface and vibration frequency.

Influencing Factors of Surface Generation in Ultra-Precision Fly Cutting

2016 ◽  
Vol 1136 ◽  
pp. 221-226
Author(s):  
Lan Zhan ◽  
Fei Hu Zhang ◽  
Chen Hui An ◽  
Zhi Peng Li
Keyword(s):  
Surface Topography ◽  
Influencing Factors ◽  
Surface Profile ◽  
Surface Generation ◽  
Cutting Machine ◽  
Fly Cutting ◽  
3D Surface ◽  
Ultra Precision ◽  
Topography Model ◽  
Great Focus

Ultra-precision fly cutting machines have long been the hardest one to compliant and induce great focus of researchers. In this paper, a surface topography model is proposed to predict the surface generation in an ultra-precision fly cutting machine. The building of surface topography model is based on the trace of the tool tip. With the 3D surface profile simulations of workpieces, several influencing factors of surface topography, especially the factors related to micro waviness error, are studied.

Size effect on surface generation of multiphase alloys in ultra-precision fly cutting

2020 ◽  
Vol 60 ◽  
pp. 23-36
Author(s):  
Guoqing Zhang ◽  
Jiaqi Ran ◽  
Suet To ◽  
Xiaoyu Wu ◽  
Peng Huang ◽  
...  
Keyword(s):  
Size Effect ◽  
Surface Generation ◽  
Fly Cutting ◽  
Multiphase Alloys ◽  
Ultra Precision

Modelling of Ultra-Precision Turning Processes in Consideration of Unbalances

2011 ◽  
Vol 223 ◽  
pp. 839-848 ◽  
Author(s):  
Christina Brandt ◽  
Jenny Niebsch ◽  
Jost Vehmeyer
Keyword(s):  
Surface Quality ◽  
High Surface ◽  
Machining Process ◽  
Surface Generation ◽  
Generation Process ◽  
Optical Components ◽  
Diamond Machining ◽  
Precision Turning ◽  
Ultra Precision ◽  
Machine Interaction

In order to manufacture optical components or mechanical parts with high surface roughness requirements, diamond machining is used. To achieve the desired surface quality, the understanding of the surface generation process and its influencing parameters is important. Here, the crucial parameter is the residual unbalance of the main spindle. As the residual un-balance affects the process and vice versa, the investigation of the process-machine interaction is necessary. In this paper we present a model describing this interaction between dynamical unbalances that occur during the machining process and the engine-shaft structure at the example of an ultra-precision turning lathe. This model allows the determination of the achievable surface quality of a workpiece for a given balancing state. On the other hand we will present a mathematical method to solve the corresponding inverse problem of computing the necessary residual balancing state and balancing weights for a given desired or given measured surface quality.

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