Research on surface topography in ultra-precision flycutting based on the dynamic performance of machine tool spindle

Xu, Yang; An, Chenhui; Wang, Zhenzhong; Wang, Quanjin; Peng, Yunfeng; Wang, Jian

doi:10.1007/s00170-016-8583-7

Cited by 20 publications

(8 citation statements)

References 14 publications

(14 reference statements)

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“…In the authors' related studies, [17][18][19] it has been confirmed that the most typical medium-frequency waviness along the cutting direction is produced by the vibration of the spindle. The mechanism of the vibration has been defined as well.…”

Section: Introductionmentioning

confidence: 87%

Dynamic performance analysis and quantitative evaluation for ultraprecision aerostatic spindle

Wei

Wang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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For optics used in high-power laser beams, high accuracy requirements in full spatial frequency must be fulfilled. Among them, the allowable root mean square value is less than 5 nm in the PSD1 band. In order to evaluate the dynamic performance of the spindle system and put forward a quantitative index, a novel accurate model of the spindle system was built and a series of dynamic simulations were performed. Harmonic response analysis reveals natural frequencies and frequency response functions. Transient analysis indicates vibration waveforms of the tool-tip. Furthermore, by analyzing surface topography, it can be found that the medium-frequency waviness in the machined surface matches the vibration waveform. Obviously, the medium-frequency waviness is generated by the modal vibration of the spindle system. So that a quantitative index for the aerostatic spindle is proposed: when the amplitude of vibration in transient analysis is smaller than 8 nm, the allowable error in the PSD1 band can be fulfilled.

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Section: Introductionmentioning

confidence: 87%

Dynamic performance analysis and quantitative evaluation for ultraprecision aerostatic spindle

Wei

Wang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Surface profiling shows that on a microscopic scale, as magnification increases, a surface profile does not tend to be a straight line but instead maintains an approximately similar shape. The state where a part of an object is similar to the whole in a certain way is called fractal, and the fractal geometry has self-similarity and scale invariance [17]. The fundamental principle of the fractal method is as follows,…”

Section: Fundamental Theory Of the Fractal Methodsmentioning

confidence: 99%

Morphological Analysis of KDP-Crystal Workpiece Surfaces Machined by Ultra-Precision Fly Cutting

et al. 2020

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Potassium dihydrogen phosphate crystals exhibit excellent nonlinear optical properties that are significantly affected by the surface morphology of the crystal. To comprehensively examine and characterize the morphological features of these crystals, the machined surfaces of workpieces are analyzed using wavelet, fractal, and power spectral density (PSD) methods. First, the fractal method is employed to analyze the features of the machined surfaces of different materials and examine the relationship between the surface roughness and fractal dimension of different materials. Then, the morphological anisotropy of the machined surfaces is analyzed using the two-dimensional PSD method. Based on the orientation of the machined surfaces of the workpieces, the tangential waves on the surfaces are analyzed using wavelet-transform and PSD methods. From a frequency-domain perspective, the scales of various influencing factor signals are identified. Additionally, the frequency range of the spindle vibration is determined based on the machining experiment. On this basis, the cause of the machined surface waviness errors is revealed.

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“…1,2 In particular, the dynamic performance of the ultra-precision flycutting machine tool has a significant impact on the surface quality due to its special processing way. 3 Large diameter optical components processed by the ultra-precision flycutting machine tool can achieve high accuracy, which surface accuracy is less than 1 mm, and the roughness is less than 3 nm. Chen et al 4,5 presented a two-round method to design a flycutting machine tool, and further studied the multi-mode vibration of the machine tool and its influence on surface generation.…”

Section: Introductionmentioning

confidence: 99%

Investigation on dynamic performance of ultra-precision flycutting machine tool based on virtual material method

Wei

Wang

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the field of ultra-precision machining, the dynamic performance of ultra-precision equipment contributes a lot to the processing accuracy. In this paper, in order to study the dynamic performance of the flycutting machine tool, the virtual material method was adopted creatively to build a machine tool model. This method overcame the complexity of actual structure and obtained more accurate results than traditional methods. Subsequently, the finite element method was applied to analyze the dynamic performance of the virtual material model. Furthermore, the modal test for the flycutting machine tool was performed to verified the simulations by means of the one-point hitting and multi-point measurement. The simulation results indicate that the virtual material model has high comprehensive accuracy, of which the average error of natural frequency is 5.9% and errors are all less than 6% excepting the first order. Moreover, combined with the flycutting experiments, it can be found that the fifth order mode of machine tool contributes a lot to processing quality, which leads to the waviness of 53 mm on the machined surface directly because of the weak stiffness of beam-column joints. By increasing the stiffness of the key joints, the waviness can be eliminated, which greatly improves the surface quality of the workpiece.

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Research on surface topography in ultra-precision flycutting based on the dynamic performance of machine tool spindle

Cited by 20 publications

References 14 publications

Dynamic performance analysis and quantitative evaluation for ultraprecision aerostatic spindle

Dynamic performance analysis and quantitative evaluation for ultraprecision aerostatic spindle

Morphological Analysis of KDP-Crystal Workpiece Surfaces Machined by Ultra-Precision Fly Cutting

Investigation on dynamic performance of ultra-precision flycutting machine tool based on virtual material method

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