Development of a virtual machining and inspection system for ultra-precision diamond turning

Abstract

The conventional approach to establish optimal processing conditions in ultraprecision diamond turning is empirical in nature. The achievement of a super mirror finish and submicrometre form accuracy in many current industrial applications still depends much on the experience and skills of the machine operators through trial cutting tests when new materials or new machine tools are used. In this paper, a virtual machining and inspection system (VMIS) is presented for ultra-precision diamond turning. The development of the VMIS aims at creating a virtual manufacturing environment for the optimization of process parameters and evaluating the quality of machined surface through various modelbased simulation modules. The VMIS is validated through a series of practical cutting tests conducted on a two-axis computer numerical control ultra-precision turning machine. The experimental results agree well with the simulated data.

Dynamic cutting process modelling and its impact on the generation of surface topography and texture in nano/micro cutting

“…7. The traditional surface generation algorithms [8][9][10][11][12][13] calculate the intersection of two adjacent tool profiles to get the boundary of each feed mark, as in Fig. 8(a).…”

“…1 The machine control loop and stiffness loop in nano/micro cutting profile superimposes on to the tool path to generate the surface topography. Lee and Cheung and colleagues [11,12] developed a dynamic cutting system to predict the surface topography in face turning. However, the cutting force model only contains the linear factors, and the whole response system was simplified into a second-order system.…”

“…For the generation algorithm of the machined surface, the most important procedure is to get the correct remaining profiles. The traditional approaches [8][9][10][11][12][13] compute the intersection of two adjacent tool profiles in order to get each tool profile boundary. However, single-point diamond turning, which is under a finer feed rate, a larger tool nose radius, a higher spindle rotational speed, and a greater unit cutting force, will be more susceptible to the effect of the tool interference [7,15].…”

Modelling and simulation of the dynamic cutting process and surface topography generation in nano/micro cutting

“…The tool profile superimposed onto the tool path to generate the surface topography. Lee and Cheung [3]- [4] built a dynamic cutting system to predict the surface topography in face turning. However the cutting force model only contained the linear factors and the whole cutting system was simplified into a second-order system.…”

A hybrid fabrication approach and profile error compensation for silicon aspheric optics

“…Ultra-precision machining is widely used for the fabrication of advanced optical components, that is, aspheric, diffractive and freeform lenses, due to its accuracy and deterministic approach. [1][2][3] Use of aspheric optics improves the performance of optical system by reducing the abrasions and system size. 4 Due to above advantages, aspheric lenses are preferred over conventional spherical lenses.…”