A Framework of a Surface Generation Model in Fast Tool Servo (FTS) Machining of Optical Microstructures

2007 ◽  
Vol 364-366 ◽  
pp. 1274-1279
Author(s):  
Tsz Chun Kwok ◽  
Chi Fai Cheung ◽  
Suet To ◽  
Wing Bun Lee
Keyword(s):  
Surface Topography ◽  
Optimization Model ◽  
Tool Path ◽  
Rotational Frequency ◽  
Cutting Conditions ◽  
Surface Generation ◽  
Tool Geometry ◽  
Generation Model ◽  
Fast Tool Servo ◽  
Topography Model

In this paper, a framework of surface generation model in the fast tool servo (FTS) machining of optical microstructures will be described. The integrated model is totally composed of a tool path generator (TPG), a surface topography model (STM) and an optimization model (OM). To develop the tool path generator, two parts should be involved. The first part is the tool path generated based on cutting conditions such as the feed rate and spindle speed, the geometry of optical microstructures, and diamond tool geometry. Another part is the synchronized motion generated by the tool actuation of the FTS at a bandwidth higher than the rotational frequency of the spindle. The surface topography model will be generated based on the TPG and used to predict the technological aspects of FTS machining. It takes into the account the kinematic and dynamic characteristics of the cutting process. The former includes the tool path generated by the tool path generator. The later includes the relative vibration between the tool and the workpiece caused by the axial error motion of the spindle as well as the synchronized motion of the FTS system. The optimization model will be undertaken by an iterative algorithm, which will be developed based on the TPG and STM. The OM will be expected to output the verified tool path, the suggested optimum cutting conditions, and the diagrams with predicted cutting performance characteristic and process parameters being investigated. Eventually, the successful development of this surface generation model can contribute for the knowledge of ultra-precision machining with FTS and the further development of the performance of the machining system.

Correlating Surface Functionality with Machining Conditions in Precision Machining Processes

2004 ◽  
Vol 471-472 ◽  
pp. 112-116
Author(s):  
X.C. Luo ◽  
K. Cheng ◽  
R. Ward
Keyword(s):  
Surface Topography ◽  
Tool Path ◽  
Surface Generation ◽  
Force Model ◽  
Generation Model ◽  
Machining Processes ◽  
Machined Surface ◽  
Surface Functionality ◽  
Precision Turning ◽  
Machining Conditions

This paper attempts to correlate surface functionality generation with machining conditions by computer simulation and machining trials. The linear and nonlinear machining conditions, such as feed rate, built-up-edge, shear- localized chip formation, regenerative chatter are modelled in the light of their physical features. They are the inputs to the integrated surface topography generation model. The dynamic tool path is calculated through the dynamic cutting force model and surface response model. The surface is generated by transforming the tool profile onto the workpiece surface along the dynamic tool path. All of these models are integrated in a user-friendly Matlab Simulink environment. On the basis of the Simulink model, the dynamic simulation is performed to predict the 3D machined surface topography and its functionality. The simulation results have been validated by precision turning trials. The spectrum analysis of the machining dynamics and surface topography shows that surface generation is highly affected by the nonlinear factors in precision turning process. A case study shows the feasibility of generating some functional surface for some product/component through controlling machining variables.

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.

Predictive Surface Generation and Characterization for Cylindrical Turning Processes

2005 ◽  
Author(s):  
Yashpal Kovvur ◽  
Hemant Ramaswami ◽  
Sam Anand
Keyword(s):  
Process Parameters ◽  
Surface Characterization ◽  
Tool Path ◽  
Surface Generation ◽  
Generation Model ◽  
Machining Parameters ◽  
Machined Surface ◽  
Motion Error ◽  
Simulation Based ◽  
Manufacturing Errors

This paper presents a generalized simulation based approach for generation and characterization of turned surfaces based on process parameters and manufacturing errors. The presented model shows that with proper analytical modeling along with appropriate process monitoring system (force signals, vibration signals, spindle motion error signals etc.,) a comprehensive surface generation model can be developed. First, the tool nose geometry and cutting-force induced vibrations are superimposed to obtain the cutting tool path. Next, the information obtained from spindle motion errors is used to analytically formulate the position of each point on the machined surface. Regression models are fit to establish the relationship between form error / surface roughness and input parameters. The simulation-based approach presented here provides a quantitative bridge between process parameters/manufacturing errors and surface characterization metrics. Such a scheme would allow manufacturing engineers to pre-select processes, parameters, and capable machines to achieve design specification. This model will allow engineers to proactively control the influence of machining parameters on product quality through computer simulation, and, thus, “do things right the first time.”

scholarly journals Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces

Materials ◽  
2018 ◽  
Vol 11 (12) ◽  
pp. 2566 ◽  
Author(s):  
Duo Li ◽  
Zheng Qiao ◽  
Karl Walton ◽  
Yutao Liu ◽  
Jiadai Xue ◽  
...  
Keyword(s):  
Surface Topography ◽  
Tool Path ◽  
Tool Path Generation ◽  
Surface Generation ◽  
Precision Machining ◽  
Path Generation ◽  
Freeform Surfaces ◽  
Ultra Precision ◽  
Slow Tool Servo ◽  
Radius Compensation

Freeform surfaces are featured with superior optical and physical properties and are widely adopted in advanced optical systems. Slow tool servo (STS) ultra-precision machining is an enabling manufacturing technology for fabrication of non-rotationally symmetric surfaces. This work presents a theoretical and experimental study of surface topography generation in STS machining of freeform surfaces. To achieve the nanometric surface topography, a systematic approach for tool path generation was investigated, including tool path planning, tool geometry selection, and tool radius compensation. The tool radius compensation is performed only in one direction to ensure no high frequency motion is imposed on the non-dynamic axis. The development of the surface generation simulation allows the prediction of the surface topography under various tool and machining variables. Furthermore, it provides an important means for better understanding the surface generation mechanism without the need for costly trial and error tests. Machining and measurement experiments of a sinusoidal grid and microlens array sample validated the proposed tool path generation and demonstrated the effectiveness of the STS machining process to fabricate freeform surfaces with nanometric topography. The measurement results also show a uniform topography distribution over the entire surface and agree well with the simulated results.

Model-Based Analysis of the Surface Generation in Microendmilling—Part I: Model Development

2006 ◽  
Vol 129 (3) ◽  
pp. 453-460 ◽  
Author(s):  
Xinyu Liu ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Stochastic Model ◽  
Surface Topography ◽  
Deterministic Model ◽  
Elastic Recovery ◽  
Chip Thickness ◽  
Surface Generation ◽  
Generation Model ◽  
Generation Process ◽  
Floor Surface ◽  
Tool Edge

This paper presents the development of models that describe the surface-generation process for microendmilling. The surface-generation models for the sidewall and floor surfaces consist of deterministic and stochastic models. In the sidewall surface-generation model, the deterministic model characterizes the surface topography generated from the relative motion between the major cutting edge and the workpiece material. The model includes the effects of the process kinematics, dynamics, tool edge serration, and process faults (e.g., tool tip runout). The stochastic model predicts the increased surface roughness generated from ploughing due to the significant tool edge radius effect. In the floor surface-generation model, the deterministic model characterizes the three-dimensional surface topography over the entire floor surface and considers the effects of the minimum chip thickness, the elastic recovery, and the transverse vibration. The variation of the ploughing amount across the swept arc of the cutter due to the varying chip load conditions is considered in the stochastic model.

scholarly journals Study of milling of low thickness thermoplastic carbon fiber composites in function of tool geometry and cutting conditions

2021 ◽  
Author(s):  
Alejandro Sambruno ◽  
Fermin Bañon ◽  
Jorge Salguero ◽  
Bartolome Simonet ◽  
Moises Batista
Keyword(s):  
Carbon Fiber ◽  
Fiber Composites ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Carbon Fiber Composites

scholarly journals An Investigation of the Cutting Strategy for the Machining of Polar Microstructures Used in Ultra-Precision Machining Optical Precision Measurement

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 755
Author(s):  
Chen-Yang Zhao ◽  
Chi-Fai Cheung ◽  
Wen-Peng Fu
Keyword(s):  
Precision Measurement ◽  
Detection Algorithm ◽  
Surface Generation ◽  
Precision Machining ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ultra Precision ◽  
Transition Points ◽  
Cutting Strategy

In this paper, an investigation of cutting strategy is presented for the optimization of machining parameters in the ultra-precision machining of polar microstructures, which are used for optical precision measurement. The critical machining parameters affecting the surface generation and surface quality in the machining of polar microstructures are studied. Hence, the critical ranges of machining parameters have been determined through a series of cutting simulations, as well as cutting experiments. First of all, the influence of field of view (FOV) is investigated. After that, theoretical modeling of polar microstructures is built to generate the simulated surface topography of polar microstructures. A feature point detection algorithm is built for image processing of polar microstructures. Hence, an experimental investigation of the influence of cutting tool geometry, depth of cut, and groove spacing of polar microstructures was conducted. There are transition points from which the patterns of surface generation of polar microstructures vary with the machining parameters. The optimization of machining parameters and determination of the optimized cutting strategy are undertaken in the ultra-precision machining of polar microstructures.

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