scholarly journals Theoretical and experimental investigation of Tool Indentation Effect in Ultra-precision Tool Servo-based Diamond Cutting of Optical Microstructured Surfaces

2021 ◽  
Author(s):  
Wei Yuan ◽  
Benny Cheung
Keyword(s):  
Experimental Investigation ◽  
Diamond Cutting ◽  
Microstructured Surfaces ◽  
Ultra Precision

scholarly journals Characterization of Surface Topography Variation in the Ultra-Precision Tool Servo-Based Diamond Cutting of 3D Microstructured Surfaces

Micromachines ◽  
2021 ◽  
Vol 12 (12) ◽  
pp. 1448
Author(s):  
Wei Yuan ◽  
Chi-Fai Cheung
Keyword(s):  
Surface Topography ◽  
Dynamic Model ◽  
Cutting Speed ◽  
Surface Generation ◽  
Dynamic Force ◽  
Diamond Cutting ◽  
Microstructured Surfaces ◽  
Ultra Precision ◽  
Cutting System

Previous models of the relative tool-work vibration are not generalized to represent the surface generation mechanism in the ultra-precision tool servo-based diamond cutting (UTSDC) of three-dimensional (3D) microstructured surfaces. This is due to the fact that the tool-work vibration in UTSDC is no longer a steady harmonic vibration with a constant amplitude but is influenced by the tool motion along the thrust direction. In this paper, dynamic modeling of the cutting system is presented for the characterization of surface topography variation in UTSDC of a microlens array considering the tool-work vibration as an underdamped vibration. The natural frequency and damping ratio of the cutting system are determined by the data-dependent systems (DDS) method. Based on the analysis of the surface profile and cutting force signals, it is found that the tool-work vibration is significantly enhanced in the cut-in process when the cutting speed increases. The simulation results show that the proposed dynamic model can well-determine root-mean-squares RMS values of the surface primary profile and the dynamic force acting on the force sensor. The dynamic model provides insight into the formation of the surface topography variation in UTSDC of 3D microstructured surfaces, and the model might be applied in self-optimized machining systems in the future.

Study on Surface Integrity of PTFE Finished by Ultra-Precision Cutting and Surface Performance

2005 ◽  
Vol 291-292 ◽  
pp. 475-482 ◽  
Author(s):  
Koichi Okuda ◽  
Masayuki Nunobiki
Keyword(s):  
Thin Film ◽  
Surface Roughness ◽  
Cutting Force ◽  
Surface Integrity ◽  
Water Repellency ◽  
Diamond Cutting ◽  
Finished Surface ◽  
Ultra Precision ◽  
Surface Performance ◽  
The Relationship

This study aims at clarifying the relationship between the surface integrity of PTFE finished by an ultra-precision diamond cutting and the adhesion strength of a metal thin film. As the first step of this study, the basic properties such as surface integrity in the diamond cutting of PTFE and the effect of the surface roughness on the textile water repellency are demonstrated in this report. The following remarks were found. The measured roughness of finished surface largely exceeded the theoretical roughness, while the cutting force was very small comparing with aluminum and the flow type chips were formed. The surface with a smaller roughness tended to repel water.

Design of Fluid Drive Spindle and Its Rotational Speed Control

2007 ◽  
Author(s):  
Yohichi Nakao ◽  
Masanori Ishikawa
Keyword(s):  
Machine Tool ◽  
Mathematical Models ◽  
Rotational Speed ◽  
Feedback Controller ◽  
Diamond Cutting ◽  
Servo Valve ◽  
Ultra Precision ◽  
Rotational Speed Control ◽  
Rotational Direction ◽  
Cutting Experiments

Water drive spindle has been developed as a spindle for ultra-precision machine tool. Performances of the water drive spindle were evaluated by experiments and simulations. In addition, the spindle was applied to diamond cutting experiments, then, successfully the fine mirrored surfaces were finished. However, rotational direction of the water drive spindle is limited, which is due to the structure of the spindle. Thus, development of water drive spindle that is capable of rotating spindle rotor for both rotational directions is current our objective. In advance of developing the water drive spindle, fluid drive spindle that is similar structure with the water drive spindle, is designed and tested in the present paper. Furthermore, control performances of the fluid drive spindle are studied through simulations. Linearized mathematical models of the fluid drive spindle and servo valve are introduced, then, they are used for the simulations. It is verified that the developed fluid drive spindle is able to rotate for both rotational directions and the spindle speed can be controlled by designed feedback controller.

The basic issues in design and fabrication of diamond-cutting tools for ultra-precision and nanometric machining

2010 ◽  
Vol 50 (4) ◽  
pp. 411-419 ◽  
Author(s):  
W.J. Zong ◽  
Z.Q. Li ◽  
T. Sun ◽  
K. Cheng ◽  
D. Li ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Diamond Cutting ◽  
Nanometric Machining ◽  
Diamond Cutting Tools ◽  
Ultra Precision

The Application of Surface Fairing Technique in Progressive Lens Processing

2007 ◽  
Vol 364-366 ◽  
pp. 1246-1250
Author(s):  
Jian Jun Du ◽  
Suet To ◽  
Chi Fai Cheung ◽  
Wing Bun Lee ◽  
Xiang Wen Miao
Keyword(s):  
Single Point ◽  
Least Square ◽  
Spline Method ◽  
Diamond Cutting ◽  
B Spline ◽  
Ultra Precision ◽  
Progressive Lenses

Based on the analysis of characteristics of progressive lens, it can be found that lens uneven change of curvature is an important reason of defect on progressive lens processed by single-point diamond cutting technique. By applying least square fairing method to fair the surface which is fitted and interpolated by Double Cubic B-Spline method, the curvature change of progressive surface becomes even. The processing experiment shows that the method in this paper can eliminate the defect effectively in the ultra-precision processing of progressive lenses.

Ultra-Precision Machining of Dies for Microlens Arrays Using a Diamond Cutting Tool

2009 ◽  
Vol 407-408 ◽  
pp. 359-362 ◽  
Author(s):  
Takehisa Yoshikawa ◽  
Masayuki Kyoi ◽  
Yukio Maeda ◽  
Tomohisa Ohta ◽  
Masato Taya
Keyword(s):  
Cutting Tool ◽  
Diamond Tool ◽  
Liquid Crystal Displays ◽  
Precision Machining ◽  
Diamond Cutting ◽  
Microlens Arrays ◽  
Synchronous Control ◽  
Ultra Precision ◽  
Diamond Cutting Tool ◽  
Cutting Unit

Patterning of numerous microlenses on a surface improves the optical performance of components such as liquid crystal displays. A cutting method using a diamond tool is examined to fabricate a molding die that employs arbitrary array patterns to mold millions of microlenses. The present paper investigates machining of microlenses on the order of 2 kHz, using a piezo-actuated micro cutting unit and a synchronous control system of the cutting unit with an NC controller. Experiments using this system revealed that it is possible to machine a large number of microlenses on a molding die with high precision.

scholarly journals Atomistic and Experimental Investigation of the Effect of Depth of Cut on Diamond Cutting of Cerium

Micromachines ◽  
2018 ◽  
Vol 9 (1) ◽  
pp. 26 ◽  
Author(s):  
Junjie Zhang ◽  
Maobing Shuai ◽  
Haibing Zheng ◽  
Yao Li ◽  
Ming Jin ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Depth Of Cut ◽  
Diamond Cutting

scholarly journals Development of an End-Toothed Disc-Based Quick-Change Fixture for Ultra-Precision Diamond Cutting

Machines ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 257
Author(s):  
Xuesen Zhao ◽  
Xiangwu Cui ◽  
Zhenjiang Hu ◽  
Qiang Zhang ◽  
Tao Sun
Keyword(s):  
Finite Element ◽  
High Precision ◽  
High Efficiency ◽  
Small Diameter ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Diamond Cutting ◽  
Positioning Accuracy ◽  
Small Depth ◽  
Ultra Precision

With its standardized and unified interface, the quick-change fixture is an important part for maintaining high efficiency without compensation of precision in the metal-turning process because it can conveniently realize high-precision repeated clamping and multi-station conversion without complex positioning and adjustment steps. However, the existing quick-change fixture products and related research cannot fully meet the needs of repeatability and applicability raised from ultra-precision, single-point diamond turning with ultra-high accuracy and ultra-small depth of cut. In this paper, we develop a quick-change fixture for ultra-precision diamond turning, in which the end-toothed disc acts as the positioning element. Specifically, the main parameters of two key components of the end-toothed disc and slotted disc spring are calculated analytically to ensure the positioning accuracy of the designed fixture used in the rotation condition, which is further ensured by controlling the machining tolerance of the tooth profile of the end-toothed disc. Additionally, finite element simulations are performed to investigate the static and modal states of the quick-change fixture, which demonstrate a maximum deformation of about 0.9 μm and a minimum natural frequency of 5655.9 Hz for the designed fixture. Two high-precision sensors are used to detect the radial jump and end run-out values after repeated clamping actions, which are employed to verify the repetitive positioning accuracy of the fixture. Subsequent finite-element simulation of the clamping of small-diameter copper bar, as well as the diamond turning experiment, jointly demonstrate that the designed fixture can achieve a precision of 1 μm. Current work provides an effective quick-change fixture to reduce the deformation of a weak-stiffness workpiece caused by clamping deformation in ultra-precision diamond cutting.

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