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

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.

Case study for sampling effect in nanometric surface roughness of ultra-precision grinding

2020 ◽  
pp. 095440892095259
Author(s):  
Shaojian Zhang ◽  
Wei Peng ◽  
Zhiwen Xiong ◽  
Suet To
Keyword(s):  
Surface Roughness ◽  
Spatial Frequency ◽  
High Spatial Frequency ◽  
Precision Grinding ◽  
Sampling Effect ◽  
Measurement Traceability ◽  
Ultra Precision ◽  
Frequency Features ◽  
Insight Into

Nanometric surface roughness (NSR) is commonly produced in ultra-precision grinding (UPG). However, the NSR would be significantly affected by the sampling frequency (SF), i.e. sampling effect, since it is governed by rich low, middle, and high spatial frequency features. Hereby, the case study focused on discussing sampling effect in the NSR of UPG. The theoretical and experimental results have been found that along with the SF increase the NSR rises and rapidly converges and the SF is over 10 times of the spatial frequency for the NSR within the 5% distortion. Moreover, the NSR is acceptable within its 5% variation ratio under two SFs. Further, the SFs should be provided as the measurement traceability, together. Significantly, the case study draws up a better insight into sampling effect in the NSR of UPG along with a feasible suggestion on its measurement.

Diamond Fly Cutting Applied to Improve Curved Surface Machining by In-Process Measurement and Control on an Ordinary Milling Machine

2020 ◽  
Author(s):  
Tatsuki Otsubo ◽  
Takanori Yazawa ◽  
Jinhui Wang ◽  
Tomonori Kato
Keyword(s):  
Diamond Turning ◽  
Milling Machine ◽  
Machined Surface ◽  
Form Accuracy ◽  
Surface Machining ◽  
Process Measurement ◽  
Fly Cutting ◽  
Ultra Precision ◽  
And Control ◽  
Measurement And Control

Abstract To improve the accuracy of the machined surface produced by an ordinary milling machine, a system called workpiece-referred form accuracy control (WORFAC) was developed and confirmed in diamond turning. However, non-rotational symmetric surface structures, such as V-grooves, pyramid structures, F-theta lenses, and other free form surface cannot be machined by diamond turning. We proposed to improve the form accuracy of a machined surface produced by an ordinary milling machine by diamond fly cutting using controlled cutting with reference surface (CCRS), an in-process measurement and control method. Fly cutting is usually used to manufacture ultra-precision microstructures with nanometric surface roughness and submicrometric form accuracy, without the need for subsequent polishing. Nevertheless, a high level of accuracy has only recently been achieved on ultra-precision milling machines. In this study, we verified the effectiveness of fly cutting with CCRS on an ordinary milling machine. CCRS improves machined surface accuracy by controlling the relative displacement between the tool and workpiece. Diamond fly cutting using CCRS was demonstrated to reduce the table motion error on an ordinary milling machine. The experiments of curved surface machining by uncontrolled machining and control machining were conducted, and the effectiveness of improving the circular are machining accuracy of the general-purpose milling machine was confirmed.

Study on the influence of spindle vibration on the surface roughness of ultra-precision fly cutting

2020 ◽  
Vol 16 (3) ◽  
pp. 258
Author(s):  
Bin Li ◽  
Zexiang Zhao ◽  
Huiying Zhao ◽  
Dongxu Ren ◽  
Jianpu Xi
Keyword(s):  
Surface Roughness ◽  
Fly Cutting ◽  
Ultra Precision ◽  
Spindle Vibration
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