Design of Ultra-Precision CNC Grinding Machine and Its Application in Machining Large Aspheric Mirrors

Large aspheric mirrors are needed for the remote sensing and ground based telescope optical systems,these mirrors are made of hard and brittle materials which require ultra-precision grinding process to guarantee the high profile accuracy and machining efficiency. The ultra-precision aspheric CNC grinding machine( UAG900) is presented by this paper,as well as its grinding capability. The hydrostatic bearings of high accuracy and stiffness are adopted by the linear and rotary motions to guarantee the mirror accuracy,material removal rate and subsurface damage. Disk type grinding wheel with arc edge is used. The material removal rate can be up to 360 mm3/ min to guarantee the machining efficiency during rough grinding using D180 diamond grinding wheel while the fine grinding is performed using D15 grinding wheel. It indicates that the grinding wheel radius measuring error is proportional to the profile error induced by the grinding path. The grinding step size is better to be 0. 01 mm for the reduction of the grinding movement accelerations and program length. The grinding path is planned and expressed based on the grinding mode according to the mirror shape. One540 mm×450 mm× 100 mm zerodur mirror is ground and re-ground using the measuring data acquired by the Leitz CMM. The final surface accuracy of P-V value is less than 5 μm after compensation grinding.

INFLUENCE OF WHEEL STRUCTURAL PARAMETERS ON MACHINING ACCURACY OF ULTRA-PRECISION PLANE HONING

A new idea for designing wheel patterns is presented so as to solve theproblems about machining accuracy of workpiece and wear of honing wheel in ultra-precision planehoning. The influence factors on motion principle and pattern structures are analyzed andoptimization machining parameters are obtained. By calculating effective cutting length on thesurface of workpiece cut by wheel's abrasive and the orbit of one point on the surface of workpiececontacting with wheel, the wear coefficient of different kinds of wheels and accuracy coefficient ofworkpiece machined by corresponding wheels are obtained. Furthermore, the simulation results showthat the optimal pattern structure of wheel turns out to have lower wheel wear and higher machiningaccuracy.

Study of material removal behavior on R-plane of sapphire during ultra-precision machining based on modified slip-fracture model

In this paper, the modified slip/fracture activation model has been used in order to understand the mechanism of ductile-brittle transition on the R-plane of sapphire during ultra-precision machining by reflecting direction of resultant force. Anisotropic characteristics of crack morphology and ductility of machining depending on cutting direction were explained in detail with modified fracture cleavage and plastic deformation parameters. Through the analysis, it was concluded that crack morphologies were mainly determined by the interaction of multiple fracture systems activated while, critical depth of cut was determined by the dominant plastic deformation parameter. In addition to this, by using proportionality relationship between magnitude of resultant force and depth of cut in the ductile region, an empirical model for critical depth of cut was developed.

Mesoplasticity Approach to Studies of the Cutting Mechanism in Ultra-precision Machining

There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.

Systematic analysis of error sources during ultra-precision machining

During ultra-precision machining, machining accuracy is determined by many factors and interaction of these factors. Error sources are systematically analyzed for ultra-precision machine tools, and the influencing degree of each factor is presented to provide orientation for error reduction and error compensation.

Nanostructured grinding wheels for ultra-precision engineering applications

Manufacturers face challenges when dealing with abrasives that lose roundness,wear excessively,and suffer from pitting of the surface of the grinding wheel that needs rectification using dressing techniques.Nanostructured abrasive grits manufactured by hybrid fusion processes and by sintering/extrusion/printing processes are found to reduce pitting quite significantly.The phenomenon of wheel collapse is increasing and cycle times developed during the grinding of aerospace alloys are much smaller compared to using conventional materials.This paper reviews the phenomenon of wheel collapse induced by pitting and takes a critical look at the production and analysis of hybrid fused and printed/sintered abrasives.A mathematical analysis is carried out of the diffusion of primary and secondary phases due to mechanical and ultrasonic agitation with the aim of producing abrasive grits with improved strength and retention.Current developments in extruded,printed,and sintered grits for use in precision grinding applications are critically reviewed.The paper concludes by explaining how such abrasives are used in practice by industrial manufacturers of high-precision products.

Research of Digital Manufacturing Technology Application on Ultra-precision Optical Workpiece Machining

Digital manufacturing technology can be used in optical field to solve many problems caused by traditional machining. According to the characters of digital manufacturing and the practical applications of ultra-precision machining,the process of digital ultra-precision machining and its technical contents were presented in this paper. In the conclusions,it was stated that the digitalization of ultra-precision machining will be an economical and efficient way for the production of new sorts of optical workpieces.

Study of CNC Grinding Machining Method About Isometric Polygon Profile

The formed principle and CNC grinding machining method of isometric polygonal profile are studied deeply and systematically. Equation about section curve of isometric polygon profile is set up by means of geometric principle. With the use of differential geometry theory, the curve is proved to be with geometric feature of convex curve. It is referred to as Isometric Polygonal Curve (IPC), because that is a kind of convex curve on which the distance between any parallel tangent lines is equal. Isometric Polygonal Profile (IPP) or Isometric Polygonal Cone Profile (IPCP) or Isometric Polygonal Topless Cone (IPTC) is formed with the IPC and straight line as generating curve. But the machining and measuring of the IPCP are so inconvenient that it has little value. Keeping in mind the characteristic of the IPP and IPTC, this paper puts forward the program method of CNC grinding machining. Isometric polygonal profile connection is a kind of polygonal profile connection. It has the superiority over keys (prismatic key & spline etc), and can be suit for the situations such as high rotative velocity, large torque, high precision, and small fixed room and vibration. Nowadays, some countries such as America, Russia, German and Switzerland applied CNC machining to the machining of polygon surface coupling parts, which makes their applications in machine productions such as motor engine, heavy machine increase day by day. But reports about concrete machining technology of isometric polygonal profile and programming of CNC machining program are very few. CNC grinding of the IPP and IPTC is one kind of the precision machining technology. It is of great importance to the popularization of the IPP and IPTC connection. From the forming mechanism, we can see that the machining and measuring of the IPP and IPTC are convenient, and therefore they have the value of the popularization. But the machining and measuring of the IPCP are so inconvenient that it has little value. In the programming the CNC grinding of the IPP and IPTC, it is more reasonable to calculate the coordinate of node according to the approaching method of equal error arc. According to the method of CNC grinding mentioned above to design the grinding machine, the structure is simple and of economical and practical.

Research on Large Depth Diameter Ratio Ultra-precision Aspheric Grinding System

In this paper, the factors of affecting surface roughness and profiles accuracy of the machined larege depth diamter ratio aspheric surfaces in ultra-precision grinding process are analyzed theoretically. An ultra-precision aspheric grinding system is then designed and manufactured. Aerostatic form is adopted to build the spindle of the workpiece, transverse guideway, longitudinal guideway and the spindle of the grinder in this system. The following specification is achieved, such as the turning accuracy of the spindle of the workpiece is 0.05 μm, radial rigidity of the spindle is GE 220N/μm, axial rigidity is GE 160 N/μm, radial rigidity of the guideway is GE 200N/μm, the highest rotational speed of the grinder is 80 000 rev/min and its turning accuracy is 0.1 μm, the resolution of linear displacement of the transverse and longitudinal guideway is 4.9 nm. Adjusting range of this adjusting mechanism is 2 mm in the Y direction, the adjusting accuracy of the precise adjusting mechanism is 0.1 μm. Micro displacement measuring system of this ultra-precision aspheric grinding adopts two-backfeed strategy, and angle displacement back-feed is realized by photoelectric encoder, it’s resolution is 655 360 pulse/rev. after 4 frequency multiplication, it’s angle displacement resolution is achieved 2 621 440 pulse/rev. Straight-line displacement is monitored by single frequency laser interferometer (DLSTAX LTM-20B, made in Japan). This CNC system adopts inimitable bi-arc step length flex CN interpolation algorithm, it’s CN system resolution is 5 nm.So this aspheric grinding system ensures profile accuracy of the machined part. The resolution of this interferometer is 5 nm. Finally, lots of ultra-precision grinding experiments are carried out on this grinding system. Some optical aspheric parts, with profiles accuracy of 0.3 μm, surface roughness less than 0.01 μm, are obtained.

Thermo-mechanical properties of bowl-shaped grinding wheel and machining error compensation for grinding indexable inserts

In order to meet the technical requirements of grinding the circumferential cutting edge of indexable inserts, thermo-mechanical properties of bowl-shaped grinding wheel in high speed grinding process and the influence of dimension variations of the grinding wheel on machining accuracy were investigated. Firstly, the variation trends of the dimension due to centrifugal force generated in different wheel speeds were studied and the effect of stress stiffening and spin softening was presented. Triangular heat flux distribution model was adopted to determine temperature distribution in grinding process. Temperature field cloud pictures were obtained by the finite element software. Then, dimension variation trends of wheel structure were acquired by considering the thermo-mechanical characteristic under combined action of centrifugal force and grinding heat at different speeds. A method of online dynamic monitoring and automatic compensation for dimension error of indexable insert was proposed. By experimental verification, the precision of the inserts satisfies the requirement of processing.

345 GHz Band-Pass Filter Using Ultra-Precision Machining Technology

This paper presents a terahertz（THz）band-pass filter using ultra-precision machining technology based on Chebyshev filter prototype.This iris inductive window coupled waveguide filter was designed by using 8 resonant cavities with a center frequency of 345 GHz and a 7% bandwidth.The final design fulfills the desired specifications and presents the minimum insertion loss of 1.55 d B and the return loss of less than 15 d B at 345 GHz.The stop-band rejection is50 d B off the center frequency about 30 GHz,which means it has a good performance of high stop-band suppression.Compared with the recent development of THz filters,this filter possesses the characteristic of simple structure and is easy to machining.

Research on CNC Turning System of Aspheric Machining Grinding Wheel

The technology of machining aspheric surface with high precision is the premise for the application of aspheric surface. The grinding machining with error compensation is a commonly used method to machine aspheric surface, which will directly influence the quality of aspheric workpiece surface. Multifunctional CNC grinding wheel truing system is a four-axis CNC truing system which can be applied to grinding wheel truing. In this system, DSP-based multi-axes motion control card is adopted as the controller, and visual C++ is used as development tool. When the design of hardware and software is completed, the system can implement truing of various grinding wheel with high precision aspheric machining such as plane grinding wheel, arc grinding one, and sphere grinding one.

Monitoring Grinding Wheel Redress-life Using Support Vector Machines

Condition monitoring is a very important aspect in automated manufacturing processes. Any malfunction of a machining process will deteriorate production quality and efficiency. This paper presents an application of support vector machines in grinding process monitoring. The paper starts with an overview of grinding behaviour. Grinding force is analysed through a Short Time Fourier Transform （STFT） to identify features for condition monitoring. The Support Vector Machine （SVM） methodology is introduced as a powerful tool for the classification of different wheel wear situations. After training with available signal data, the SVM is able to identify the state of a grinding process. The requirement and strategy for using SVM for grinding process monitoring is discussed, while the result of the example illustrates how effective SVMs can be in determining wheel redress-life.

RESEARCH ON MODELING AND CHARACTERISTICS OF THE SPINDLE DYNAMIC COUPLING ABSORBERING SYSTEM OF A SUPER-PRECISION SURFACE GRINDING MACHINE

The bearing is described by constrain matrix, and the spindle system of a NCsurface grinding machine is simplified as elastic-coupling beam, then modal synthesis method is usedto establish the dynamic model of beam. Moreover, the response of the end of rotor is analyzed, andthe natural frequency, principle mode and other dynamic characteristics of the coupling system arestudied, the law of bearing stiffness to coupling frequency and amplitude of rotor is also found.Finally, according to the actual condition, a dynamic absorber is designed. The simulation andexperimental results show that the amplitude of spindle can be declined effectively when the dynamicabsorber is attached.

Dynamic Accuracy Design Method of Ultra-precision Machine Tool

Ultra-precision machine tool is the most important physical tool to machining the workpiece with the frequency domain error requirement, in the design process of which the dynamic accuracy design(DAD) is indispensable and the related research is rarely available. In light of above reasons, a DAD method of ultra-precision machine tool is proposed in this paper, which is based on the frequency domain error allocation.The basic procedure and enabling knowledge of the DAD method is introduced. The application case of DAD method in the ultra-precision flycutting machine tool for KDP crystal machining is described to show the procedure detailedly. In this case, the KDP workpiece surface has the requirements in four different spatial frequency bands, and the emphasis for this study is put on the middle-frequency band with the PSD specifications. The results of the application case basically show the feasibility of the proposed DAD method. The DAD method of ultra-precision machine tool can effectively minimize the technical risk and improve the machining reliability of the designed machine tool. This paper will play an important role in the design and manufacture of new ultra-precision machine tool.

Development of CAD/CAM system and profile measuring device for CNC grinding machine to obtain an optimal grinding speed

Cam mechanics is one of the most popular devices for generating irregular motions and is widely used in automatic equipment,such as textile machines,internal combustion engines,and other automatic devices.In order to obtain a positive motion from the follower using a rotating cam,its shape should be correctly designed and manufactured.The development of an adequate CAD/CAM system for a cam profile CNC grinding machine is necessary to manufacture high-precision cams.The purpose of this study is the development of a CAD/CAM system and profile measuring device for a CNC grinding machine to obtain an optimal grinding speed with a constant surface roughness.Three types of disk cams were manufactured using the proposed algorithm and procedures to verify effectiveness of the developed CAD/CAM system.

3D printing for ultra-precision machining:current status,opportunities,and future perspectives

Additive manufacturing,particularly 3D printing,has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency.However,3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish,accuracy,and mechanical properties.Ultra-precision machining(UPM)is a potential machining technology that addresses these challenges by enabling high surface quality,accuracy,and repeatability in 3D-printed components.This study provides an overview of the current state of UPM for 3D printing,including the current UPM and 3D printing stages,and the application of UPM to 3D printing.Following the presentation of current stage perspectives,this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other.In particular,future opportunities focus on cutting tools manufactured via 3D printing for UPM,UPM of 3D-printed components for real-world applications,and post-machining of 3D-printed components.Finally,future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed.This study concludes that UPM is a promising technology for 3D-printed components,exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications.It also discusses how UPM and 3D printing can complement each other.

Experimental Study of Machinability in Millgrinding of SiCp/Al Composites

An attempt was made to investigate the machinability of Si Cp/Al composites based on the experimental study using mill-grinding processing method. The experiments were carried out on a high-speed CNC machining center using integrated abrasive cutting tool. The effects of combined machining parameters, e g, cutting speed（vs）, feed rate（vf）, and depth of cut（ap）, with the same change of material removal rate（MRR） on the mill-grinding force and surface roughness（Ra） were investigated. The formation mechanism of typical machined surface defects was analyzed by SEM. The experimental results reveal that with the same change of material removal rate, lower mill-grinding force values can be gained by increasing depth of cut and feed rate simultaneously at higher cutting speed. With the same change of MRR value, lower surface roughness values can be gained by increasing the feed rate at higher cutting speed, rather than just increasing the depth of cut, or increasing the feed rate and depth of cut simultaneously. The machined surface of Si Cp/Al composites reveals typical defects which can influence surface integrity.

Dynamic modeling of ultra-precision fly cutting machine tool and the effect of ambient vibration on its tool tip response

The dynamic performances of an ultra-precision fly cutting machine tool(UFCMT)has a dramatic impact on the quality of ultra-precision machining.In this study,the dynamic model of an UFCMT was established based on the transfer matrix method for multibody systems.In particular,the large-span scale flow field mesh model was created;and the variation in linear and angular stiffness of journal and thrust bearings with respect to film thickness was investigated by adopting the dynamic mesh technique.The dynamic model was proven to be valid by comparing the dynamic characteristics of the machine tool obtained by numerical simulation with the experimental results.In addition,the power spectrum density estimation method was adopted to simulate the statistical ambient vibration excitation by processing the ambient vibration signal measured over a long period of time.Applying it to the dynamic model,the dynamic response of the tool tip under ambient vibration was investigated.The results elucidated that the tool tip response was significantly affected by ambient vibration,and the isolation foundation had a good effect on vibration isolation.

Theoretical Study on Non-transmission High Efficient Parallel Camber Grinding Machine

Be directed against the development trend of modern CNC grinding machine towards high precision and high efficiency, some general weaknesses of existing camber grinding machine are analyzed in detail. In order to develop new type CNC camber grinding machine that can grind complex die, and genuinely achieved accurate feed and high efficient grinding, a new type camber grinding machine is put forward, called non-transmission virtual-shaft CNC camber grinding machine. Its feed system is a parallel mechanism that is directly driven by linear step motor. Therefore, traditional transmission types, such as the ball lead-screw mechanisms, the gears, the hydraulic transmission system, etc. are cancelled, and the feed system of new type CNC camber grinding machine can truly possess non-creep, good accuracy retentiveness a wide range of feed-speed change, high kinematical accuracy and positioning precision, etc. In order to realize that the cutting motion is provided with high grinding speed, step-less speed variation, high rotational accuracy, good dynamic performance, and non-transmission, the driving technology of hollow rotor motor is applied to drive the spindle of new type grinding machine,thus leading to the elimination of the transmission parts of cutting motion. The principle structure model of new type camber grinding machine is advanced. The selection, control gist and driving circuit line of the linear step motor are expounded. The main technology characteristics and application advantages of non-transmission virtual-shaft CNC camber grinding machine are introduced.