Abstract
Ultra-precision single-point diamond flycutting (SPDF) is an irreplaceable technology for cutting KH2PO4 (KDP) crystals with large size. However, some undesirable waviness errors along feed-direction exist on the machined surface, which could greatly deteriorate the optical performance of KDP crystals. The spindle dynamic characteristic of SPDF plays an important role in the formation of such waviness errors. This paper presents an on-line measurement method with five-capacitance displacement sensors in nanometer range for monitoring the motion errors of the aerostatic spindle. An error transform theory which is based on kinematic error propagation was introduced to obtain the three-dimensional trajectory of the cutting tool. Then, the spindle motion errors and the cutting tool trajectory were analyzed in frequency domain to investigate the main source of the waviness errors. Simultaneously, the three-dimensional topography of work-piece was simulated by combining the motion trajectory and the geometrical morphology of the cutting tool. The results showed that the waviness errors along feed-direction were caused by the spindle rotation fluctuation with a frequency about 10.8 Hz, and the topography simulations showed good agreement with the machining results. Besides, the experimental results indicated that the error can be diminished by changing the spindle control system to the digital control method. This study established the contact between the measured spindle motion errors and the machined surfaces, which contributes to deeper understanding of the dynamic characteristics of the spindle in SPDF.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Burkhart SC, Bliss E, Di NP, Kalantar D, Lowe-Webb R, Mccarville T (2011) National ignition facility system alignment. Appl Opt 50(8):1136–1157
Moses EI (2008) The national ignition facility and the golden age of high energy density science. Pulsed Power Conference, IEEE Int 36:16–19
Chabassier G (1999) Using a design of experiment method to improve KDP crystal machining process 3492:814–820
Liang YC, Chen WQ, Bai QS, Sun YZ, Chen GD, Zhang Q, Sun Y (2013) Design and dynamic optimization of an ultraprecision diamond flycutting machine tool for large KDP crystal machining. Int J Adv Manuf Technol 69(1):237–244
Sun YZ, Chen WQ, Liang YC, An CH, Chen GD, Su H (2015) Dynamic error budget analysis of an ultraprecision flycutting machine tool. Int J Adv Manuf Techol 76(5):1215–1224
Chen WQ, Liang YC, Sun YZ, An CH, Chen GD (2014) Investigation of the influence of constant pressure oil source fluctuations on ultra-precision machining. Proc Instit Mech Eng Part B: J Eng Manuf 229(2):372–376
Chen WQ, Sun YZ, An CH, Su H, Yang K, Zhang Q (2015) Modeling and simulation of the interaction of manufacturing process and machine tool structure in flycutting machining. Proc Instit Mech Eng Part C: J Eng Sci 229(15):2730–2736
Liang YC, Chen WQ, An CH, Luo XC, Chen GD, Zhang Q (2013) Investigation of the tool-tip vibration and its influence upon surface generation in flycutting. Proc Instit Mech Eng Part C: J Eng Sci 228(12):2162–2167
Sun YZ, Chen WQ, Liang YC, An CH, Chen GD, Su H (2014) An integrated method for waviness simulation on large-size surface. Proc Instit Mech Eng Part B: J Eng Manuf 229(1):178–182
Li MQ, Chen MJ, An CH, Zhou L, Cheng J, Xiao Y, Jiang W (2012) Mechanism of micro-waviness induced KH2PO4 crystal laser damage and the corresponding vibration source. Chinese Phys B 21(5):34–42
An CH, Zhang Y, Xu Q, Zhang FH, Zhang JF, Zhang LJ, Huang JH (2010) Modeling of dynamic characteristic of the aerostatic bearing spindle in an ultra-precision fly cutting machine. Int J Mach Tools Manuf 50(4):374–385
Yang X, An CH, Wang ZZ, Wang QJ, Peng YF, Wang J (2016) Research on surface topography in ultra-precision flycutting based on the dynamic performance of machine tool spindle. Int J Adv Manuf Technol 2016:1–9
Lee JC, Gao W, Shimizu Y, Hwang J, Oh JS, Park CH (2012) Spindle error motion measurement of a large precision roll lathe. Int J Precis Eng Manuf 13(6):861–867
Anandan KP, Ozdoganlar OB (2013) Analysis of error motions of ultra-high-speed (uhs) micromachining spindles. Int J Mach Tools Manuf 70(7):1–14
Anandan KP, Tulsian AS, Donmez A, Ozdoganlar OB (2011) A technique for measuring radial error motions of ultra-high-speed miniature spindles used for micromachining. Precis Eng 36(1):104–120
Zhang SJ, To S, Cheung CF, Wang HT (2012) Dynamic characteristics of an aerostatic bearing spindle and its influence on surface topography in ultra-precision diamond turning. Int J Mach Tools Manuf 62(1):1–12
Zhang SJ, To S, Zhang GQ, Zhu ZW (2015) A review of machine-tool vibration and its influence upon surface generation in ultra-precision machining. Int J Mach Tools Manuf 91:34–42
Chen GD, Sun YZ, An CH, Zhang FH, Sun ZJ, Chen WQ (2016) Measurement and analysis for frequency domain error of ultra-precision spindle in a flycutting machine tool. Proceedings of the Institution of Mechanical Engineers. Part B: J Eng Manuf
Chen DJ, Gao X, Dong LH, Fan JW (2016) An evaluation system for surface waviness generated by the dynamic behavior of a hydrostatic spindle in ultra-precision machining. Int J Adv Manuf Technol 91(5–8):2185–2192
Chen DJ, Zhou S, Dong LH, Fan JW (2016) An investigation into error source identification of machine tools based on time-frequency feature extraction. Shock Vib 2016:1–10
Funding
This research was supported by the Science Challenge Project (no. JCKY2016212A506-0504) and the Science and Technology Research Program of Chongqing Municipal Education Commission (no. KJ1704087).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
An, C., Deng, C., Miao, J. et al. Investigation on the generation of the waviness errors along feed-direction on flycutting surfaces. Int J Adv Manuf Technol 96, 1457–1465 (2018). https://doi.org/10.1007/s00170-018-1720-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-1720-8