Surface generation of freeform surfaces in diamond turning by applying double-frequency elliptical vibration cutting

Zhou, Xiaoqin; Zuo, Chengming; Liu, Qiang; Lin, Jieqiong

doi:10.1016/j.ijmachtools.2015.11.012

Cited by 52 publications

(21 citation statements)

References 26 publications

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“…The simplification enabled the assumption that the machining part was a tilted flat surface instead of a curvilinear surface. This simplification is often used for the analysis of the machining process of curved surfaces [22,23,24,25,26]. The assumption enables the reduction of the number of variables by excluding the impact of the curvature surface radius.…”

Section: Methodsmentioning

confidence: 99%

Research and Method of Roughness Prediction of a Curvilinear Surface after Titanium Alloy Turning

2019

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This paper deals with the optimization of process parameters (such as cutting speed and feed rate) to minimize surface roughness in the turning of a titanium alloy (Ti-6Al-4V) workpiece with spherical shape. In the first part of the article, based on the results analysis, a mathematical model is developed. It is shown that cutting speed has little effect on the surface roughness. The second part of the paper presents the application of the developed method to optimize cutting data such as feed rate in order to obtain the surface roughness parameters Ra and Rz of the curvilinear surface of the titanium alloy workpiece at acceptable and aligned, values regardless of the surface shape and its tilted angle. A case study verifies the correctness of the proposed method. The machining time was substantially shortened in comparison to the non-optimized cutting process.

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Section: Methodsmentioning

confidence: 99%

Research and Method of Roughness Prediction of a Curvilinear Surface after Titanium Alloy Turning

2019

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“…In contrast, non-resonant mode vibration cutting is typically accomplished using a piezo-driven flexure mechanism that can operate at a range of continuous frequencies. The frequency and amplitude of the output trajectory can be adjusted flexibly during non-resonant vibration cutting operations, so this machining method provides greater flexibility in the machining of certain complex and difficult-to-machine surfaces [20,21]. However, for the current research, the non-resonant vibration mode cutting has a lower operating frequency, resulting in lower machining efficiency and poor surface quality.…”

Section: Introductionmentioning

confidence: 99%

Development of Piezo-Actuated Two-Degree-of-Freedom Fast Tool Servo System

et al. 2019

Self Cite

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Fast tool servo (FTS) machining technology is a promising method for freeform surfaces and machining micro-nanostructure surfaces. However, limited degrees of freedom (DOF) is an inherent drawback of existing FTS technologies. In this paper, a piezo-actuated serial structure FTS system is developed to obtain translational motions along with z and x-axis directions for ultra-precision machining. In addition, the principle of the developed 2-DOF FTS is introduced and explained. A high-rigidity four-bar (HRFB) mechanism is proposed to produce motion along the z-axis direction. Additionally, through a micro-rotation motion around flexible bearing hinges (FBHs), bi-directional motions along the x-axis direction can be produced. The kinematics of the mechanism are described using a matrix-based compliance modeling (MCM) method, and then the static analysis and dynamic analysis are performed using finite element analysis (FEA). Testing experiments were conducted to investigate the actual performance of the developed system. The results show that low coupling, proper travel, and high natural frequency are obtained. Finally, a sinusoidal wavy surface is uniformly generated by the mechanism developed to demonstrate the effectiveness of the FTS system.

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“…The fast tool servo (FTS) (Okazaki, 1990;Dow, 1991;Rasmussen et al, 1994;Zhu et al, 2001; Rakuff and Cuttino, 2009;Zhou et al, 2016) was developed in order to achieve high-efficiency machining for workpieces with non-circular or non-axisymmetric surfaces, such as optical components. The FTS allows machining of non-axisymmetric surfaces by controlling the cutting tool to synchronize the cutting direction with the rotation of the workpiece at high speed using a piezoelectric actuator or a voice coil actuator.…”

Section: Introductionmentioning

confidence: 99%

Improvement of machining accuracy for 3D surface machining with CNC lathe

Takasugi

Morimoto²,

Kaneko³

et al. 2018

JAMDSM

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The present paper describes a new non-axisymmetric curved surface turning (NACS-Turning) method. Fast tool servo (FTS) technology has been widely researched and developed. However, the movable range of the FTS is limited to a few millimeters owing to its mechanism. Therefore, in the present study, we describe the development of a new NACS-Turning method that can realize long stroke and high bandwidth in the cutting direction (X-axis) of the turning tool by using a linear motor. We confirmed that NACS-Turning could machine a non-axisymmetric workpiece while the X-axis slide was synchronized at an acceleration of 4.5 ɡ with a spindle rotation of 750 min-1. However, in this machining method, the machining accuracy deteriorates depending on the acceleration and cutting reaction force of the X-axis slide. In particular, excess from the designed allowable acceleration threatens to cause a serious machining error. Therefore, the present paper describes the possibility of machining considering the acceleration and improvement of machining accuracy in NACS-Turning. We examine the relationships between machining parameters and the accelerations as well as the tool path generation method considering these relationships. Moreover, machining accuracy is improved by on-machine measurement. We constructed a system whereby a re-machining tool path is generated by measuring the profile of the machined workpiece and feeding the measurement results back to the CAM. As a result, we obtained a theorem for the possibility of machining via NACS-Turning and confirmed the improvement in accuracy.

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Surface generation of freeform surfaces in diamond turning by applying double-frequency elliptical vibration cutting

Cited by 52 publications

References 26 publications

Research and Method of Roughness Prediction of a Curvilinear Surface after Titanium Alloy Turning

Research and Method of Roughness Prediction of a Curvilinear Surface after Titanium Alloy Turning

Development of Piezo-Actuated Two-Degree-of-Freedom Fast Tool Servo System

Improvement of machining accuracy for 3D surface machining with CNC lathe

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