Analysis and comparison of two different ultra-precision manufacturing methods for off-axis parabolic mirror with single point diamond turning

Ji, Shijun; Yu, Huijuan; Zhao, Jun; Liu, Xiaolong; Hu, Ming

doi:10.1177/0954405415625457

Cited by 4 publications

(3 citation statements)

References 27 publications

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“…Hence, to achieve very high resolution and accuracy, FTS is often used for freeform surfaces ultraprecision machining. 7,8 There are potential challenges towards ultraprecision machining of non-rotational symmetry (NRS) surfaces through diamond turning. 9 During the machining process, the diamond tool has to move as a function of the spindle rotation and translation of the machine slide.…”

Section: Introductionmentioning

confidence: 99%

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Investigation on multi-body dynamics based approach to the toolpath generation for ultraprecision machining of freeform surfaces

Khaghani

Cheng

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article presents an innovative approach to toolpath generation for ultraprecision machining of freeform optic surfaces based on the principle of Automatic Dynamics Analysis of Mechanical Systems. As components with freeform surfaces often have non-rotational symmetry, there are potential challenges facing their ultraprecision machining through single-point diamond turning, such as the projected points in complex large sag surfaces, which likely find it difficult to communicate with the control system and, thus, do not perform successfully. In ultraprecision machining, to achieve the highest performance in freeform surface resolution, the factors of dynamics, material and mechanical stiffness, frictions, tooling and accuracy of the servo component should be considered. The investigation is focused on an integrated approach and the associated scientific understanding of precision engineering design, ultraprecision machining and metrology of freeform surfaces as well as their application perspective. In this approach, the toolpath for very complex freeform surfaces can be generated using the Newton–Raphson method to solve the kinematics and dynamics equations of motion. The effect of friction and contact force are also investigated for accurate toolpath curve generation. Moreover, the Gear stiff (GSTIFF)/ Wielenga stiff (WSTIFF) integrator for solving the non-linear equations of motion is employed, and the result shows the time step size, playing a critical role in generating toolpath curves with a higher accuracy and resolution.

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Section: Introductionmentioning

confidence: 99%

“…Hence, to achieve very high resolution and accuracy, FTS is often used for freeform surfaces ultraprecision machining. 7,8…”

Section: Introductionmentioning

confidence: 99%

Investigation on multi-body dynamics based approach to the toolpath generation for ultraprecision machining of freeform surfaces

Khaghani

Cheng

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Two different ultra-precision manufacturing methods for off-axis parabolic mirror with single point diamond turning are analyzed and compared by Shijun Ji et al, the two methods are that turning the cylindrical blank by revolving around the axis of the parabolic surface and revolving around the axis of cylindrical surface, besides, the kinematic analyses of two linear axes (X, Z) are studied, the tool path generation and installation errors are analyzed under two different conditions. Experimental results of off-axis parabolic mirror show that the surface machined with turning the cylindrical blank by revolving around the axis of parabolic surface has better machining quality than the other one [ 8 ]. The cylindrical coordinate micromachining method for ultra-precision cutting of sinusoidal surfaces was studied by Xiaodong Zhang et al, a three-axis turning machine is used and a spiral curve NC path is adopted, meanwhile, they proposed a method to optimize the tool geometry and to simulate the cutting process, a sinusoidal surface with 5.54 nm in Ra are achieved in their study [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Ultra-Precision Machining of a Compound Sinusoidal Grid Surface Based on Slow Tool Servo

Zhao

et al. 2018

Materials

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Compound sinusoidal grid surface with nanometric finish plays a significant role in modern systems and precision calibrator, which can make the systems smaller, the system structure more simple, reduce the cost, and promote the performance of the systems, but it is difficult to design and fabricate by traditional methods. In this paper, a compound freeform surface constructed by a paraboloidal base surface and sinusoidal grid feature surface is designed and machined by slow tool servo (STS) assisted with single point diamond turning (SPDT). A novel combination of the constant angle and constant arc-length method is presented to optimize the cutting tool path. The machining error prediction model is analyzed for fabricating the compound sinusoidal grid surface. A compound sinusoidal grid surface with 0.03 mm amplitude and period of 4 is designed and cutting process is simulated by use of MATLAB software, machining experiment is done on ultra-precision machine tool, the surface profile and topography are measured by Taylor Hobson and Keyence VR-3200, respectively. After dealing with the measurement data of compound freeform surface, form accuracy 4.25 μm in Peak Village value (PV), and surface roughness 89 nm in Ra are obtained for the machined surface. From the theoretical analysis and experimental results, it can be seen that the proposed method is a reasonable choice for fabricating the compound sinusoidal grid surface.

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An equivalent-sphere-based grinding of large aspheric and spherical surfaces

Dong

et al. 2022

Int J Adv Manuf Technol

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Analysis and comparison of two different ultra-precision manufacturing methods for off-axis parabolic mirror with single point diamond turning

Cited by 4 publications

References 27 publications

Investigation on multi-body dynamics based approach to the toolpath generation for ultraprecision machining of freeform surfaces

Investigation on multi-body dynamics based approach to the toolpath generation for ultraprecision machining of freeform surfaces

Ultra-Precision Machining of a Compound Sinusoidal Grid Surface Based on Slow Tool Servo

An equivalent-sphere-based grinding of large aspheric and spherical surfaces

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