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Hybrid tool servo diamond turning of multiscale optical surface based on spectral separation of tool path

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Abstract

Multiscale optical surface (MOS) that contains non-rotational symmetry micro-features and large sag height macro-features is promising in optics, due to their special optical advantages. Diamond turning with the slow tool servo (STS) or fast tool servo (FTS) is widely used for fabricating optical surfaces. However, due to the limited dynamic performance of STS and the small stroke of FTS, applying STS or FTS alone cannot efficiently fabricate MOS. Therefore, in this paper, a hybrid tool servo (HTS) diamond turning technique was presented to efficiently produce MOS. By integrating characters of the high dynamic performance of FTS and long stroke of STS, the new technique fulfills the strict requirements of manufacturing MOS. Methods for generating tool path in CAD software and separating the tool path into STS path and FTS path based on its spectral features were proposed. Besides, tool path evaluations were conducted to predict the profile errors with considering the dynamic performance of STS and FTS, based on the suitable machining parameters selected. A machining experiment of a typical MOS was carried out using the proposed technique. Results showed that the MOS was efficiently fabricated with no tool interference mark on the fabricated surface and a maximum profile error of about 2.8 μm.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

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Code availability

The codes used during the current study are available from the corresponding author on reasonable request.

Funding

This work was supported by the Laboratory of Precision Manufacturing Technology, CAEP (grant number KF15002), and the National Natural Science Foundation of China (grant number 51405315).

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Authors and Affiliations

  1. School of Mechanical Engineering, Sichuan University, Chengdu, 610065, China

    Shengyuan Yang, Deping Yu, Xiaoming Liu & Zhengxin Yin

  2. The Laboratory of Precision Manufacturing Technology, China Academy of Engineering Physics, Chengdu, 610200, China

    Hong Yang & Yanbing Feng

Authors
  1. Shengyuan Yang
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  2. Deping Yu
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  3. Hong Yang
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  4. Yanbing Feng
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  5. Xiaoming Liu
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  6. Zhengxin Yin
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Corresponding author

Correspondence to Deping Yu.

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Yang, S., Yu, D., Yang, H. et al. Hybrid tool servo diamond turning of multiscale optical surface based on spectral separation of tool path. Int J Adv Manuf Technol 116, 145–157 (2021). https://doi.org/10.1007/s00170-021-07406-7

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  • DOI: https://doi.org/10.1007/s00170-021-07406-7

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