Full-band error control and crack-free surface fabrication techniques for ultra-precision fly cutting of large-aperture KDP crystals

2017 ◽  
Vol 12 (2) ◽  
pp. 193-202 ◽  
Author(s):  
F. H. Zhang ◽  
S. F. Wang ◽  
C. H. An ◽  
J. Wang ◽  
Q. Xu
Keyword(s):  
Free Surface ◽  
Error Control ◽  
Large Aperture ◽  
Fly Cutting ◽  
Full Band ◽  
Ultra Precision ◽  
Surface Fabrication ◽  
Kdp Crystals

scholarly journals Effect of KDP-Crystal Material Properties on Surface Morphology in Ultra-Precision Fly Cutting

Micromachines ◽  
2020 ◽  
Vol 11 (9) ◽  
pp. 802
Author(s):  
Dongju Chen ◽  
Shupei Li ◽  
Jinwei Fan
Keyword(s):  
Surface Morphology ◽  
Material Properties ◽  
Force Model ◽  
Gradient Plasticity ◽  
Cutting Force Model ◽  
Kdp Crystal ◽  
Crystal Material ◽  
Fly Cutting ◽  
Ultra Precision ◽  
Kdp Crystals

To study the effect of material properties on the surface morphology of potassium dihydrogen phosphate (KDP) crystals, an ultra-precision fly cutting machine tool with a single-point diamond tool was used to perform a cutting experiment on (100) crystal plane of the KDP crystal. The elastic modulus, shear modulus, hardness, and dislocation of KDP crystals are taken into the cutting force model by introducing the strain gradient plasticity theory. Since the size effect and dynamic response will affect the surface roughness during ultra-precision machining, the surface roughness of workpieces in ultra-precision fly cutting is hard to predict. Based on the previously established strain gradient plasticity theoretical model, cutting force model, and the dynamic characteristics of the ultra-precision fly cutting system, a surface morphology prediction model under the influence of KDP crystal material properties was established. Finally, the accuracy of the surface morphology prediction model was verified by ultra-precision fly cutting experiments, and identified the frequency range of the characteristic signal caused by the anisotropy of the KDP crystal from the frequency, thereby verifying the KDP crystal material properties has a significant effect on the surface of the machined workpiece roughness.

Case study of surface micro-waves in ultra-precision raster fly cutting

2016 ◽  
Vol 46 ◽  
pp. 393-398 ◽  
Author(s):  
Guoqing Zhang ◽  
Suet To ◽  
Shaojian Zhang ◽  
Zhiwei Zhu
Keyword(s):  
Fly Cutting ◽  
Ultra Precision

Ultra-precision detection of surface defects of large aperture diffraction grating based on machine vision

2021 ◽  
Author(s):  
Haotian Wang ◽  
Chaoming Li ◽  
Xinrong Chen ◽  
Zhe Huang ◽  
Jiayao Pan ◽  
...  
Keyword(s):  
Machine Vision ◽  
Diffraction Grating ◽  
Surface Defects ◽  
Large Aperture ◽  
Ultra Precision ◽  
Aperture Diffraction

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.

Characteristics of Laser-Induced Surface Damage on Large-Aperture KDP Crystals at 351 nm

2015 ◽  
Vol 32 (2) ◽  
pp. 027801 ◽  
Author(s):  
Ye Tian ◽  
Wei Han ◽  
Hua-Bao Cao ◽  
Fu-Quan Li ◽  
Bin Feng ◽  
...  
Keyword(s):  
Surface Damage ◽  
Large Aperture ◽  
Kdp Crystals

Fabrication of Micro Tetrahedron Patterns Using Ultra-Precision Shaping System

2008 ◽  
Vol 381-382 ◽  
pp. 469-472
Author(s):  
J.W. Park ◽  
Soo Chang Choi ◽  
H.S. Oh ◽  
Yong Woo Kim ◽  
S.W. Kim ◽  
...  
Keyword(s):  
High Intensity ◽  
Three Dimensional ◽  
Precision Machining ◽  
Machining Errors ◽  
High Form ◽  
Shaping System ◽  
Information And Communication ◽  
Ultra Precision ◽  
Surface Fabrication ◽  
Micro Patterns

Recently, ultra-precision machining of components and dies for information and communication industries, such as fresnel mirrors, diffraction lens, and die for super high intensity reflective sheet is one of the major target. To machine three-dimensional micro patterns, such as super high-intensity reflective sheets, ultra-precision and mirror surface fabrication processes are required. It has been reported, however, that continuous cutting, such as turning or shaping, is more suitable to ultra-precision machining. Many researchers have studied the manufacturing process of reflective sheet dies to obtain high form accuracy and surface quality. In this paper, ultra-precision shaping system was developed to fabricate micro patterns mechanically. In order to estimate performance of the shaping system, micro V-shaped grooves and tetrahedron pattern arrays for a super high intensity reflective sheet was applied. Also, a new measuring technology to inspect form and machining errors of a machined tetrahedron patterns was proposed. The results show that shaping system has a positioning accuracy of x, y, z axis with 100, 10, 10nm resolution, respectively. Micro V-shaped grooves could be machined at various depths and micro tetrahedron patterns with a good quality were obtained as well.

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.

Sign in / Sign up

Export Citation Format

Share Document