Theoretical and experimental investigation of spindle axial drift and its effect on surface topography in ultra-precision diamond turning

Wu, Quanhui; Sun, Yazhou; Chen, Wanqun; Chen, Guoda

doi:10.1016/j.ijmachtools.2017.01.006

Cited by 26 publications

(6 citation statements)

References 12 publications

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“…Their theoretical results prove that the slide straightness and angular errors result in the oscillating and tilting surface profile, while the vibrations can cause the segments on the machined surface as demonstrated in Figure 8. Bittner et al and Wu et al considered the tilt error between the moving direction of the diamond tool and the spindle axis, and pointed out this error can lead to a conical profile error on the machined surface topography [95,96].…”

Section: Theoretical Modelsmentioning

confidence: 99%

“…However, it is such to accurately match the corresponding points between the two profiles. To solve this problem, some researchers [28,96] attempted to employ the 2D surface topography, i.e., the radial or circumferential surface profile to evaluate the prediction accuracy, which can be regarded as a local validation method. Meanwhile, some other researchers [85,86,87] compare the surface roughness between the two profiles to validate the accuracy.…”

Section: Future Workmentioning

confidence: 99%

See 1 more Smart Citation

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Zong

2019

Micromachines

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In this work, the influencing factors and corresponding theoretical models for the surface topography in diamond turning process are reviewed. The surface profile on one tool feed is the elementary unit of surface topography. The influences coupled with the models of the duplication effect of the tool edge profile, material spring back, and plastic side flow are outlined in this part. In light of the surface profile on one tool feed and “trim principle”, the modeling methods of surface topography along the radial direction (2D surface topography) are commented. Moreover, the influence of the vibration between the diamond tool and workpiece on the 2D surface topography is discussed, and the theoretical models are summarized. Finally, the issues for modeling of 3D surface topography, particularly the influences of material defects, are analyzed. According to the state-of-the-art surface topography model of the diamond turned component, future work in this field is therefore predicted.

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Section: Theoretical Modelsmentioning

confidence: 99%

Section: Future Workmentioning

confidence: 99%

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Zong

2019

Micromachines

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“…In order to fully analyze the characteristics, Cui et al [ 16 ] used dynamic grid technology and finite element method to quantitatively study the impact of manufacturing errors on the operating accuracy of ABS. Huang et al [ 17 ] studied the variation of the spindle average sliding axis error, and found the spindle average sliding axis error increasing with the spindle speed [ 18 ]. Chen et al [ 19 ] analyzed the relationship between the vibration frequency during the machining process and the spatial vibration frequency of the machined surface.…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Micro Cutting Mechanism and Surface Topography Generation in Ultraprecision Diamond Turning

Chen

Liu³

et al. 2022

Micromachines

Self Cite

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Revealing forming mechanism of workpiece surface topography plays an important role in improving ultraprecision turning. In this paper, the forming mechanism of the turning workpiece surface topography is analyzed and verified by the theoretical simulation and experiment respectively. First, the factors directly related to the turning process are analyzed, and a volumetric error model is built and discussed, which considered geometric errors, tool geometry, spindle vibrations, feed rate, cut depth, and feed system position change. The vibration mechanism and laws of the spindle system under multi-field coupling is analyzed, and the effect of the spindle axial vibration on the turning surface topography is studied. In addition, influence of coupled vibrations on the turning surface texture is analyzed, and an equivalent machining model is constructed to identify crucial geometric errors of the workpiece surface topography. Finally, a homemade ultraprecision machine tool system is built and used for turning the workpiece surface, and the tested results of the surface topography demonstrate Ra is better, 10 nm and Rv is better, 20 nm. The end face of the workpiece forms periodically fluctuating wave and ripple patterns, and the comparison between theoretical analysis and experimental detection of the surface topography is verified.

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“…Miyatake et al 9 similarly investigated the high-speed stability of aerostatic porous journal bearings. Wu et al 10 used experimental methods to prove and measure the presence of axial drift of the spindle in the machining process, and also to study the effect of spindle drift error on the machined surface. Tanaka et al 11 investigated various factors affecting the rigidity and rotational accuracy of a self-throttled static air spindle.…”

Section: Introductionmentioning

confidence: 99%

Numerical study on the rotational and machining accuracy of an end-milling process with spindles supported by aerostatic bearings

Shimada

Wakabayashi

Shimoyakawa

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Aerostatic bearings are widely used for spindles in ultra-precision machining tools. These spindles consist of a pair of aerostatic thrust bearings and several aerostatic journal bearings. The rotational accuracy of aerostatic spindles depends largely on the arrangement and performance of the individual bearings, but the evaluation of the rotational accuracy is mainly carried out experimentally using a prototype machine, which poses challenges in terms of the time and cost of building a prototype. Therefore, a real need exists to evaluate the spindle characteristics by numerical calculation. In this study, we developed a method to numerically calculate the trajectory of the spindle rotator which is supported by aerostatic bearings. The method was developed to numerically investigate and determine the effects on the rotational accuracy of the spindle during end milling when the cutting force is applied to the rotating rotor. A comparison was made regarding the amount of runout of the rotating shaft when side milling was performed using a spindle with a shaft diameter of 22 mm and a small end mill with a diameter of 1 mm, concerning three different spindles with different arrangements of thrust and journal bearings. The effects of rotational speed, radial depth of cut, and the number of tool teeth on the runout of the rotating shaft were numerically verified. As a result, it was found that a spindle structure in which the thrust bearing is placed on the tool side and the journal bearing span is lengthened is desirable.

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Theoretical and experimental investigation of spindle axial drift and its effect on surface topography in ultra-precision diamond turning

Cited by 26 publications

References 12 publications

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

Investigation on the Micro Cutting Mechanism and Surface Topography Generation in Ultraprecision Diamond Turning

Numerical study on the rotational and machining accuracy of an end-milling process with spindles supported by aerostatic bearings

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