Study on suppressing cutting force fluctuations based on chip loads for turning optical freeform surfaces
- 197 Downloads
The optics with micro-structures and freeform surfaces, which have a broader range of applications, can be generally fabricated by the single-point diamond turning (SPDT) with fast tool servo. But the cutting chatters caused by the cutting force fluctuations (CFFs) will greatly deteriorate the processing qualities like forming accuracy and surface finish; thus, this paper will build an improved chip load model (CLM) to simply characterize the cutting forces. Based on the modified CLM, two types of turning approaches with constant chip load (CCL) are developed to suppress CFFs, but which have some serious limitations in their practical applications. As an improvement, a type of simple-yet-effective virtual tool radius (VTR) method is further developed for practically generating the pre-turning toolpaths of the blank surfaces, which can ensure the uniform cutting allowances in finish turning. Taking two typical surfaces as examples, the proposed VTR method is analytically compared to the traditional processes in terms of chip load, and their resistances to the undulations of chip loads are also examined in detail. Finally, the VTR approach and traditional process are experimentally investigated by turning the sinusoidal radial surface on brass cylinders, and their cutting forces are measured for validating the CFF rejection capacities.
KeywordsCutting chatter Cutting force fluctuation Chip load Diamond turning Optical freeform surface
Unable to display preview. Download preview PDF.
- 10.Lin C-M, Tarn-Sea L Robust controllers design of constant turning force feedback control system. In: Industrial Automation and Control: Emerging Technologies, 1995., International IEEE/IAS Conference on, 22-27 May 1995 1995. pp 637–643. doi: 10.1109/IACET.1995.527633
- 12.Tang L, Cheng Z, Huang J, Gao C, Chang W (2015) Empirical models for cutting forces in finish dry hard turning of hardened tool steel at different hardness levels. Int J Adv Manuf Technol 76 (1):691–703. doi: 10.1007/s00170-014-6291-8
- 15.Shaw, MC (2005) Metal cutting principles (2nd Edition). Oxford University Press,Google Scholar
- 16.Armarego, EJA, Brown RH (1969) The machining of metals. Prentice-HallGoogle Scholar
- 17.Song W (2006) Development of predictive force models for classical orthogonal and oblique cutting and turning operations incorporating tool flank wear effects. Queensland University of technologyGoogle Scholar
- 18.Dan. L (2012) A constant chip-load turning apporach to generating freeform optical surfaces M.S., Jilin UniversityGoogle Scholar
- 24.Imani BM, El-Mounayri H, Hosseini, SA (2007) Analytical Chip Load Prediction for Rough End Mills. 2nd Tehran International Congress on Manufacturing Engineering-TICME2007. December 10–13, 2007, Tehran, Iran.Google Scholar
- 28.Cardi AA (2009) On the development of a dynamic cutting force model with application to regenerative chatter in turning. Ph.D., Georgia Institute of Technology, Ann ArborGoogle Scholar
- 32.Yang P, Qian X (2008) Adaptive slicing of moving least squares surfaces: toward direct manufacturing of point set surfaces. J Comput Inf Sci Eng 8(3). doi: 10.1115/1.2955481