Simulation of single-point diamond turning fabrication process errors

Juergens, Richard C.; Shepard, R. Hamilton; Schaefer, John P.

doi:10.1117/12.511341

Cited by 18 publications

(8 citation statements)

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“…It is very important to know what may cause the spindle star form error since each machine may operate at different spindle speeds. However, both these articles [9] and [11] addressed the source of such error as coming from the spindle axial motion due to the imbalance in the air-bearing spindle system.…”

Section: Figure 1: Spindle Star Formation On a Diamond Turned Copper mentioning

confidence: 98%

“…Finally, vibrations of the spindle perpendicular to the workpiece can result in azimuthal ripples on the surface forming the spindle star pattern. Again, according to Juergens et al, [11], spindle star can be caused by imbalance of the workpiece on the machine and a properly designed spindle generally produces little or no spindle star. The size and location of the air bearing orifice can cause axial oscillations of the spindle; however, newer spindles all have continuous air slots based on the use A c c e p t e d M a n u s c r i p t 7 of porous bearing materials.…”

Section: Introductionmentioning

confidence: 99%

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Form error in diamond turning

Tauhiduzzaman

Yip

Veldhuis

2015

Precision Engineering

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Section: Figure 1: Spindle Star Formation On a Diamond Turned Copper mentioning

confidence: 98%

Section: Introductionmentioning

confidence: 99%

Form error in diamond turning

Tauhiduzzaman

Yip

Veldhuis

2015

Precision Engineering

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“…This has already been described in detail 10 . The DPT process can introduce many types of errors, such as vertex cusps if the tool axis is not aligned with the rotation axis, radial ripples resulting in mid-frequency errors, azimuthally symmetric ripple, called spindle star, and other effects.…”

Section: Able To Model Tolerances Not Built-in the Programmentioning

confidence: 95%

Random thoughts on Monte Carlo tolerancing

Juergens

Wood

2007

SPIE Proceedings

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Optical design and analysis software codes usually have built-in capabilities for performing rapid tolerance studies on optical systems. However, these built-in capabilities often work on only a few selected performance metrics, such as RMS spot size, MTF, or RMS wavefront error. To tolerance an optical system with other performance metrics, such as ensquared energy, often requires using different techniques. A common method used is Monte Carlo tolerancing. Monte Carlo tolerancing has advantages and disadvantages as compared to using the tolerancing methods built-in to commercial optics codes. This paper discusses many of these advantages and disadvantages.

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“…SPDT is featured with the spectrum of operating parameters, which needs fine tuning to achieve the best results. This is practically not possible due to tool offset errors, thermal effects, uneven tool wear, spindle vibration and centripetal distortions (Juergens et al, 2003). Residual turning marks are the most important factors limiting the performance in this process.…”

Section: Introductionmentioning

confidence: 99%

An experimental study on the effect of magneto-rheological finishing on diamond turned surfaces

Khatri

Tewary

Mishra

et al. 2013

Journal of Intelligent Material Systems and Structures

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Magneto-rheological materials are a class of smart materials whose rheological properties can be rapidly varied by applying a magnetic field. Magneto-rheological finishing utilizes magneto-rheological fluid, which consists of magnetic particles, non-magnetic abrasives and some additives in water or other carrier to polish the materials. Single-point diamond turning is able to remove hundreds of microns of material and generate surface with micron accuracies. Residual turning marks are the most important factor limiting the performance in diamond turning process. Magneto-rheological finishing has inherent ability to improve micro-roughness, remove subsurface damage and reduce residual stresses induced during diamond turning process. Combining single-point diamond turning and magneto-rheological finishing creates a deterministic process for manufacturing highly finished surfaces. In this article, an attempt has been made to improve the finish of diamond turned surface with magneto-rheological finishing and to investigate the effects of parameters like current, spacing, wheel speed, feed rate and magnetic field on the final surface finish. Based on the parametric study, an optimum combination of process parameters is identified using analysis of variance. Various image processing techniques have been used for the comparison of the surface analysis of diamond turned surfaces and the magneto-rheological finished surfaces.

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Simulation of single-point diamond turning fabrication process errors

Cited by 18 publications

References 0 publications

Form error in diamond turning

Form error in diamond turning

Random thoughts on Monte Carlo tolerancing

An experimental study on the effect of magneto-rheological finishing on diamond turned surfaces

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