In some special fields such as precision optics, the part surface has strict requirements on the frequency domain errors, besides the conventional spatial domain errors such as surface roughness error. In light of the available works lacking of the frequency domain error analysis in ultra-precision flycutting, this paper therefore presents its frequency domain error analysis. A case study of KDP crystal flycutting is carried out to show its detailed processes, where the processing parameters, tool geometry, motion dynamic error of the machine guideway and tool-work vibration induced dynamic error are considered. A surface profile generation method is put forward. Two cases with different tool-work vibration frequencies are carried out. The spatial frequency spectrum is obtained based on the FFT analysis of the generated profile in the specified direction. After the in-depth analysis, the inherent correlation of the generated spatial frequency components with feed spatial frequency and machine dynamic errors induced spatial frequency under certain machining conditions are found, which is very meaningful for the frequency domain error prediction in the real application. The proposed analysis method can also be applied into other types of surface machining.
Error Analysis of Radial Motion Measurement of Ultra-Precision Spindle
