Abstract
Ultra-precision machining (UPM) typically involves ultra-precision diamond turning (UPDT), ultra-precision raster milling (UPRM), and ultra-precision grinding (UPG). In UPM, spindle vibration (SV) is a natural feature majorly influencing surface topography. In this paper, a dynamic model for SV was generalized to study its distinctive effects on surface topography in different UPM processes. The theoretical results were identified well by a series of cutting tests. In UPDT, constant cutting forces induce harmonic SV to produce regular patterns. In UPRM, periodical impulsive cutting forces cause periodical impulsive SV to generate quasi-regular patterns. In UPG, random impulsive cutting forces result in partially random impulsive SV to form partially random patterns. The generalized model can be employed to predict the effects of SV on surface generation in UPM.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
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
Zhang SJ, To S, Wang SJ, Zhu ZW (2015) A review of surface roughness generation in ultra-precision machining. Int J Mach Tools Manuf 91:76–95
Cheung CF, Lee WB (2000) Study of factors affecting the surface quality in ultra-precision diamond turning. Mater Manuf Process 15(4):481–502
Chen X, Xu J, Fang H, Tian R (2017) Influence of cutting parameters on the ductile-brittle transition of single-crystal calcium fluoride during ultra-precision cutting. Int J Adv Manuf Technol 89(1–4):219–225
Takeuchi Y, Sakaida Y, Sawada K, Sata T (2000) Development of a 5-axis control ultraprecision milling machine for micromachining based on non-friction servomechanisms. CIRP Ann Manuf Technol 49:295–298
Chen W, Lu L, Yang K, Huo D, Su H, Zhang Q (2015) A novel machine tool design approach based on surface generation simulation and its implementation on a fly cutting machine tool. Int J Adv Manuf Technol 80:829–837
Chen W, Luo X, Su H, Wardle F (2016) An integrated system for ultra-precision machine tool design in conceptual and fundamental design stage. Int J Adv Manuf Technol 84(5–8):1177–1183
Wang SJ, To S, Chan CY, Cheung CF, Lee WB (2010) A study of the cutting-induced heating effect on the machined surface in ultra-precision raster milling of 6061 Al alloy. Int J Adv Manuf Technol 51:69–78
Wang SJ, To S, Chen X, Chen XD (2015) An investigation on surface finishing in ultra-precision raster milling of aluminum alloy 6061. Proc Inst Mech Eng Part B-J Eng Manuf 229(8):1289–1301
Fang FZ, Liu YC (2004) On minimum exit-burr in microcutting. J Micromech Microeng 14:984–988
Sun Y, Chen W, Liang Y, An C, Chen G, Su H (2015) Dynamic error budget analysis of an ultraprecision fly cutting machine tool. Int J Adv Manuf Technol 76:1215–1224
Peng Y, Jiang T, Ehmann KF (2014) Research on single-point diamond fly-grooving of brittle materials. Int J Adv Manuf Technol 75:1577–1586
Chen Y-L, Cai Y, Shimizu Y, Ito S, Gao W, Ju B-F (2016) On-machine measurement of microtool wear and cutting edge chipping by using a diamond edge artifact. Precis Eng 43:462–467
Evans CJ, Browy EC, Childs THC, Paul E (2015) Interferometric measurements of single crystal diamond tool wear. CIRP Ann Manuf Technol 64:125–128
Chen Y-L, Wang S, Shimizu Y, Ito S, Gao W, Ju B-F (2016) An in-process measurement method for repair of defective microstructures by using a fast tool servo with a force sensor. Precis Eng 39:134–142
Zhou X, Zuo C, Liu Q, Lin J (2016) Surface generation of freeform surfaces in diamond turning by applying double-frequency elliptical vibration cutting. Int J Mach Tools Manuf 104:45–57
Chan CY, Li LH, Lee WB, Wong HC (2016) Monitoring life of diamond tool in ultra-precision machining. Int J Adv Manuf Technol 82(5–8):1141–1152
An CH, Zhang Y, Xu Q, Zhang FH, Zhang JF, Zhang LJ, Wang JH (2010) Modeling of dynamic characteristic of the aerostatic bearing spindle in an ultra-precision fly cutting machine. Int J Mach Tools Manuf 50:374–385
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 62:1–12
Zhang SJ, To S, Wang HT (2013) A theoretical and experimental investigation into five-DOF dynamic characteristics of an aerostatic bearing spindle in ultra-precision diamond turning. Int J Mach Tools Manuf 71:1–10
Chen D, Gao X, Dong L, Fan J (2017) 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
Funding
This work was supported by the National Natural Science Foundation of China (Grants no. 51405217), the Science Foundation of Jiangxi Province of China (Grants no. 20161BBE50055 and 20142BAB216025), and the Youth Science Foundation of Jiangxi Educational Committee of China (Grant no. GJJ4210).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Dong, Z., Zhang, S., Xiong, Z. et al. A generalized dynamic model for spindle vibration influencing surface topography in different ultra-precision machining processes. Int J Adv Manuf Technol 96, 2471–2478 (2018). https://doi.org/10.1007/s00170-018-1814-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-1814-3