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Tool Path Generation for Multi-Degree-of-Freedom Fast Tool Servo Diamond Turning of Optical Freeform Surfaces

  • H. B. CaiEmail author
  • G. Q. Shi
Article
  • 4 Downloads

Abstract

Fast tool servo diamond turning is one of the most important techniques for machining optical freeform surfaces. The tool path has a significant effect on roughness, waviness and profile errors. However, the mapping mechanism between the tool path and the surface form error is not precisely expressed. The paper presents a novel approach for modelling and simulation of the tool path generation in fast tool servo diamond turning. The approach, by analyzing scallop-height, linearization error and tool nose radius compensation, models the tool path generation process. The effects and characteristic of an optimized tool path are investigated through simulations. Experiments have been carried out to show that the model is feasible.

Keywords

Freeform surfaces Fast tool servo Tool path generation Active control accuracy model Profile errors 

Nomenclature

ρ

linear motion of the x-axis

θ

rotation motion of the c-axis

D

workpiece diameter

ɑf

feedrate

ω

angular velocity of the spindle

t

processing time

PV

form error of freeform surface

PVe

form error predicted of freeform surface

PVfd

form error in feedrate direction

PVcd

form error in cutting direction

hsh

cutting scallop-height in the feed direction

hcav

scallop-height of the concave curvature surface

hvex

scallop-height of the convex curvature surface

R(m,n)

curvature radius of the freeform surface

si

cutter-contact point

er

cutting linearization error

z(s)

freeform surface curve

g(s)

tool trajectory in the z-direction

Δε

search step in the iterative solution method

δ

tolerance in the iterative solution method

n

normal vector of CCPs

r

tool nose radius

Ra

surface roughness

Notes

References

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Copyright information

© The Society for Experimental Mechanics, Inc 2019

Authors and Affiliations

  1. 1.College of Mechanical and Electric EngineeringChangchun University of Science and TechnologyChangchunChina
  2. 2.Suzhou Institute of Biomedical Engineering and Technology Chinese Academy of SciencesSuzhouChina

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