Design of a Fast Tool Servo Based Diamond Turning Machine for Fabricating Micro-Structured Surfaces

2010 ◽  
Vol 443 ◽  
pp. 669-674 ◽  
Author(s):  
De Ping Yu ◽  
Sze Wei Gan ◽  
Yoke San Wong ◽  
Mustafizur Rahman ◽  
Geok Soon Hong
Keyword(s):  
High Accuracy ◽  
Design Criterion ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Structured Surfaces ◽  
Structured Surface ◽  
Increasing Demand

Increasing demand for ultraprecision components with micro-structured surfaces has attracted focus on diamond turning research. In this paper, a fast tool servo (FTS) based diamond turning machine is presented for fabricating micro-structured surfaces with high accuracy. A design criterion is established to serve as a guide in choosing or designing a suitable type of FTS for a micro-structured surface. Experiments on fabricating sampled micro-structured surfaces are carried out to demonstrate the effectiveness of the designed FTS based diamond turning machine.

Ductile-Regime Machining for Fast Tool Servo Diamond Turning of Micro-Structured Surfaces on Brittle Materials

2012 ◽  
Vol 500 ◽  
pp. 333-338 ◽  
Author(s):  
De Ping Yu ◽  
Yoke San Wong ◽  
Geok Soon Hong
Keyword(s):  
Experimental Investigation ◽  
Brittle Material ◽  
Brittle Materials ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Entire Surface ◽  
Structured Surfaces ◽  
Simulation Based ◽  
Ductile Regime Machining ◽  
Machining Characteristics

Micro-structured surfaces on brittle materials, e.g. ceramic and glass, are gaining increasing application in a range of areas. In this paper, fast tool servo (FTS) diamond turning has been applied to machine micro-structured surfaces on brittle materials and the machined surfaces has been observed to study its machining mechanism. A machining model is presented to enable ductile-regime machining of the brittle material. Based on the model, machining characteristics can be predicted for given cutting conditions. Experimental investigation on machining of a micro-structured surface verified that ductile-regime machining can be ensured on the entire surface through path planning simulation based on the machining model.

Integral Sliding Mode Control for Fast Tool Servo Diamond Turning of Micro-Structured Surfaces

2011 ◽  
Vol 5 (1) ◽  
pp. 4-10 ◽  
Author(s):  
De Ping Yu ◽  
◽  
Geok Soon Hong ◽  
Yoke San Wong
Keyword(s):  
Sliding Mode Control ◽  
Sliding Mode ◽  
Diamond Turning ◽  
Machining Process ◽  
Fast Tool Servo ◽  
Form Error ◽  
Structured Surfaces ◽  
Integral Sliding Mode Control ◽  
Integral Sliding Mode ◽  
Mode Control

Fast Tool Servo (FTS) diamond turning is a promising machining process for fabricating high precision micro-structured surfaces. However, the dynamics of FTS affects its performance and causes form error in the machined surfaces, thus shortening the useful bandwidth of the FTS for precision machining. In this paper, an Integral Sliding Mode Control (ISMC) algorithm is proposed to control the FTS in order to achieve the desired closed-loop dynamics. The robustness of the ISMC to disturbance and model uncertainties or variations is ensured by the implementation of disturbance estimation and an integral switching control action. The influence of the FTS dynamics can thereby be minimized by modifying the tool path offline with the inverse of the desired dynamics. Experiments on machining of typical micro-structured surfaces show that the proposed method is effective in reducing the FTS dynamics induced form error in the machined surface.

Fabrication of Micro-Structured Surfaces on Bulk Metallic Glasses Based on Fast Tool Servo Assisted Diamond Turning

2012 ◽  
Vol 4 (9) ◽  
pp. 906-911 ◽  
Author(s):  
Zhiwei Zhu ◽  
Xiaoqin Zhou ◽  
Qiang Liu ◽  
Jieqiong Lin ◽  
Shaoxin Zhao
Keyword(s):  
Metallic Glasses ◽  
Bulk Metallic Glasses ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Structured Surfaces

Turning of Micro-Structured Surfaces Based on a Fast Tool Servo System

2014 ◽  
Vol 684 ◽  
pp. 308-312 ◽  
Author(s):  
Xiao Hui Wang ◽  
Zhi Ding ◽  
Yu Zhen Ma
Keyword(s):  
Piezoelectric Actuator ◽  
Closed Loop ◽  
Tracking Error ◽  
Servo System ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Precision Engineering ◽  
Loop Control ◽  
Structured Surfaces ◽  
Grid Surface

A fast tool servo system is developed for the fabrication of micro-structured surface on a diamond turning machine. The fast tool servo (FTS) system in this investigation employs a piezoelectric actuator to actuate the diamond tool and a capacitance probe as the feed back sensor. To compensate the inherent nonlinear hysteresis behavior of the piezoelectric actuator, Proportional Integral (PI) closed loop control with a feed-forward predictor is implemented. The result of closed loop experiment in FTS demonstrates that the tracking error has been reduced to a level of less than 150nm. Actual experiment of fabricating the sinusoidal grid surface was performed on an ultra-precision diamond turning machine designed by Center of Precision Engineering of HIT. The fabrication of a sinusoidal grid surface has indicated the effectiveness of the fabrication system.

Optimized tool path generation for fast tool servo diamond turning of micro-structured surfaces

2012 ◽  
Vol 63 (9-12) ◽  
pp. 1137-1152 ◽  
Author(s):  
De Ping Yu ◽  
Sze Wei Gan ◽  
Yoke San Wong ◽  
Geok Soon Hong ◽  
Mustafizur Rahman ◽  
...  
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Diamond Turning ◽  
Path Generation ◽  
Fast Tool Servo ◽  
Structured Surfaces

Automatic Surface Characterization for Micro-Structured Surfaces Fabricated by Fast Tool Servo Diamond Turning

2010 ◽  
Vol 447-448 ◽  
pp. 534-538 ◽  
Author(s):  
De Ping Yu ◽  
Yoke San Wong ◽  
Geok Soon Hong
Keyword(s):  
Surface Characterization ◽  
General Purpose ◽  
Diamond Turning ◽  
Surface Measurement ◽  
Fast Tool Servo ◽  
Measurement Instruments ◽  
Form Error ◽  
Form Accuracy ◽  
Structured Surfaces ◽  
Resolution Measurement

Fast tool servo diamond turning is a promising machining method for precision and complex micro-structured surfaces with spatial wavelength above tens of microns. It is crucial to measure and characterize the micro-structured surfaces to sub-micrometer form accuracy. The general purpose measurement instruments are not able to evaluate the true form accuracy between the measured surface and designed surface. Therefore, in this paper an automatic surface characterization method is proposed to evaluate the form accuracy for micro-structured surfaces. The fabricated surfaces can be measured by any high-resolution measurement instruments. After the surface measurement, an iterative closest point (ICP) algorithm is modified to align the measured surfaces to the designed surfaces with the form error evenly distributed over the whole surface. After alignment, the designed surface height corresponding to each measured point is calculated to form the areal error map. 3D surface parameters are chosen and calculated from the error map to characterize the surface form error. Experimental results demonstrate the effectiveness of the proposed surface characterization method.

Adaptive Diamond Turning for Micro-Structured Surfaces

2016 ◽  
Vol 679 ◽  
pp. 163-166 ◽  
Author(s):  
Zhi Wei Zhu ◽  
Suet To
Keyword(s):  
Numerical Simulation ◽  
Basic Principle ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Shape Variation ◽  
Homogeneous Surface ◽  
Local Shape ◽  
Structured Surfaces ◽  
Sampling Intervals ◽  
Linearization Errors

In this paper, adaptive diamond turning (ADT) is proposed for micro-structured surfaces to obtain homogeneous surface quality without loss of efficiency. With consideration of the local shape variation of desired surfaces, the adaptation in feeding direction is to actively control motions along the x-axis to obtain constant scallop heights, whereas the adaptation in forwarding direction is to vary angular sampling intervals to obtain constant linearization errors. The basic principle of ADT is demonstrated, and unique features of the corresponding motions of the machine tool are detailed by numerical simulation. Two degree-of-freedoms fast tool servo or slow slide servo-based turning is strongly recommended to meet the requirements of the ADT method.

Tri-axial Fast Tool Servo Using Hybrid Electromagnetic-Piezoelectric Actuation for Diamond Turning

2021 ◽  
pp. 1-1
Author(s):  
Zi-Hui Zhu ◽  
Li Chen ◽  
Yuhan Niu ◽  
Xiaonan Pu ◽  
Peng Huang ◽  
...  
Keyword(s):  
Diamond Turning ◽  
Piezoelectric Actuation ◽  
Fast Tool Servo

scholarly journals Investigation of the Impact of Micro-Structuring on the Bonding Performance of Beechwood (Fagus Sylvatica L.)

Forests ◽  
2022 ◽  
Vol 13 (1) ◽  
pp. 113
Author(s):  
Destin Bamokina Moanda ◽  
Martin Lehmann ◽  
Peter Niemz
Keyword(s):  
Bond Strength ◽  
Waiting Time ◽  
Type I ◽  
Bond Quality ◽  
Structured Surfaces ◽  
Structured Surface ◽  
Bonding Performance ◽  
Delamination Resistance ◽  
Micro Structuring ◽  
The Impact

Although glueing softwood is well mastered by the industry, predicting and controlling bond quality for hardwood is still challenging after years of research. Parameters such as the adhesive type, resin–hardener ratio, and the penetration behaviour of the wood are determinants for the bond quality. The aim of this work was to assess to what extent the glueing behaviour of beechwood can be improved by using structural planing. The different surfacing methods were characterised by their roughness. The bond strength of the micro-structured surfaces was determined according to EN 302-1, and the delamination resistance was tested as indicated by EN 302-2 for type I adhesives. Micro-structured surfaces were compared with different surfaces (generated by surfacing methods such as dull/sharp planing and sanding). In dry test conditions, all surfacing methods gave satisfying results. In the wet stage, the bond strength on the finer micro-structured surface slightly outperformed the coarse structure surface. For the delamination resistance, a clear improvement could be observed for melamine-formaldehyde-bonded specimens since, when using the recommended amount of adhesive, micro-structured surfaces fulfilled the requirements. Nevertheless, structural planing cannot lead to a reduction in the applied grammage since no sample with a smaller amount fulfilled EN 302-2 requirements even by observing the recommended closed assembly waiting time. Adhesion area enlargement of the micro-structuring is minor. The good delamination performance without waiting time (CAT) is not caused by surface enlargement, since finer micro-structured surface with negligible area increase and delivered even better delamination resistance. Subsurface analysis should be carried out to thoroughly investigate this phenomenon.

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