Abstract
This paper presents the design and dynamic optimization of an ultraprecision diamond flycutting machine tool for producing flat half-meter-scale optics. A novel tool holder is designed, which can achieve micron-level axial feeding and tool angle accurate adjustment, and new technology is also used to allow alignment of the spindle axis to the horizontal-slide travel. The design and characteristic analyses of this machine tool are presented, including the static, modal, harmonic, and rotor dynamic analysis for predicting its static and dynamic performance. A prototype is built based on the analysis and FE model considering the joint parameters. The machining test shows that this machine tool can successfully produce 415 × 415-mm surfaces on aluminum and crystalline optics, with 1.3-μm flatness and 2.4-nm rms roughness. Moreover, the differences of design concepts are discussed between the ultraprecision machine tool for optical parts machining and the conventional machine tool.
Similar content being viewed by others
References
Painsner JA, Boyes JD, Kuopen SA (1994) National ignition facility. Laser Focus World 30(5):75
Lin ZQ, Dong X (1999) SG-II laser elementary research and precision SG-II program. Fusion Eng Design 44(1):61–66
Chen MJ, Pang QL, Wang JH, Cheng K (2008) Analysis of 3D microtopography in machined KDP crystal surfaces based on fractal and wavelet methods. Int J Mach Tool Manuf 48(7–8):905–913
Montesanti RC, Locke SF, Thompson SL, Cass CL, Wulff TA (2000) Vertical-axis diamond flycutting machine for producing flat half-meter-scale optics. Optical Fabrication and Testing, OSA Technical Digest (Optical Society of America): paper OWA2.
Takasu S, Msduda M, Nishiguchi T (1985) Influence of study vibration with small amplitude upon surface roughness in diamond machining. Annals of the CIRP 34(1):463–467
Chen JS, Hsu WY (2006) Dynamic and compliant characteristics of a Cartesian-guided tripod machine. J Manuf Sci Eng 128(2):494–502
Daisuke K, Thomas L, Sascha W, Konrad W (2010) Evaluation of modeling approaches for machine tool design. Precis Eng 34(3):399–407
Altintas Y, Okwudire CE (2009) Dynamic stiffness enhancement of direct-driven machine tools using sliding mode control with disturbance recovery. Annals of the CIRP 58(1):335–338
Bohez ELJ (2002) Five-axis milling machine tool kinematic chain design and analysis. Int J Mach Tool Manuf 42(4):505–520
Huo DH, Cheng K, Wardle F (2010) Design of a five-axis ultra-precision micro-milling machine-UltraMill. Part 1: holistic design approach, design considerations and specifications. Int J Adv Manuf Technol 47(9–12):867–877
Huo DH, Cheng K, Wardle F (2010) Design of a five-axis ultra-precision micro-milling machine-UltraMill. Part 2: integrated dynamic modelling, design optimisation and analysis. Int J Adv Manuf Technol 47(9–12):879–890
Cheng X, Wang ZG, Kobayashi S, Nakamoto K, Yamazaki K (2010) Tool fabrication system for micro/nano milling-function analysis and design of a six-axis wire EDM machine. Int J Adv Manuf Technol 46(1–4):179–189
Lu XD, Paone MP, Usman I, Moyls B, Smeds K, Rotherhofer G, Slocum AH (2009) Rotary–axial spindles for ultra-precision machining. Ann CIRP 58(1):323–326
Wardle FP, Bond C, Wilson C, Cheng K, Huo D (2010) Dynamic characteristics of a direct-drive air-bearing slide system with squeeze film damping. Int J Adv Manuf Technol 47(9–12):911–918
Kono D, Lorenzer T, Weikert S, Wegener K (2010) Evaluation of modeling approaches for machine tool design. Precis Eng 34(3):399–407
Yigit AS, Ulsoy AG (2002) Dynamic stiffness evaluation for reconfigurable machine tools including weakly non-linear joint characteristics. Proceedings of the Institution of Mechanical Engineers. Part B: J Eng Manuf 216(1):87–101
Lee SW, Mayor R, Ni J (2006) Dynamic analysis of a mesoscale machine tool. J Manuf Sci Eng 128(1):194–203
Keisuke N, Toyoka I, Naohiro O, Masayuki N, Tetsuya H (2009) Automatic unbalance correction of rotors by sympathetic phase inversion of ultraviolet-curing resin. Precis Eng 33(3):243–247
Tu JF, Gehrich MJ, Shih AJ (1998) Experimental study of a precision, hydrodynamic wheel spindle for submicron cylindrical grinding. Precis Eng 22(1):43–57
Junichi A, Ryo K, Tomoyasu T, Takaaki O, Akira C (2012) Reduction of force interference and performance improvement of a consequent-pole bearingless motor. Precis Eng 36(1):10–18
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Liang, Y., Chen, W., Bai, Q. et al. Design and dynamic optimization of an ultraprecision diamond flycutting machine tool for large KDP crystal machining. Int J Adv Manuf Technol 69, 237–244 (2013). https://doi.org/10.1007/s00170-013-5020-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-5020-z