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Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces

Freeform surfaces are featured with superior optical and physical properties and are widely adopted in advanced optical systems. Slow tool servo (STS) ultra-precision machining is an enabling manufacturing technology for fabrication of non-rotationally symmetric surfaces. This work presents a theore...

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Detalles Bibliográficos
Autores principales: Li, Duo, Qiao, Zheng, Walton, Karl, Liu, Yutao, Xue, Jiadai, Wang, Bo, Jiang, Xiangqian
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2018
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6316587/
https://www.ncbi.nlm.nih.gov/pubmed/30562973
http://dx.doi.org/10.3390/ma11122566
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author Li, Duo
Qiao, Zheng
Walton, Karl
Liu, Yutao
Xue, Jiadai
Wang, Bo
Jiang, Xiangqian
author_facet Li, Duo
Qiao, Zheng
Walton, Karl
Liu, Yutao
Xue, Jiadai
Wang, Bo
Jiang, Xiangqian
author_sort Li, Duo
collection PubMed
description Freeform surfaces are featured with superior optical and physical properties and are widely adopted in advanced optical systems. Slow tool servo (STS) ultra-precision machining is an enabling manufacturing technology for fabrication of non-rotationally symmetric surfaces. This work presents a theoretical and experimental study of surface topography generation in STS machining of freeform surfaces. To achieve the nanometric surface topography, a systematic approach for tool path generation was investigated, including tool path planning, tool geometry selection, and tool radius compensation. The tool radius compensation is performed only in one direction to ensure no high frequency motion is imposed on the non-dynamic axis. The development of the surface generation simulation allows the prediction of the surface topography under various tool and machining variables. Furthermore, it provides an important means for better understanding the surface generation mechanism without the need for costly trial and error tests. Machining and measurement experiments of a sinusoidal grid and microlens array sample validated the proposed tool path generation and demonstrated the effectiveness of the STS machining process to fabricate freeform surfaces with nanometric topography. The measurement results also show a uniform topography distribution over the entire surface and agree well with the simulated results.
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spelling pubmed-63165872019-01-08 Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces Li, Duo Qiao, Zheng Walton, Karl Liu, Yutao Xue, Jiadai Wang, Bo Jiang, Xiangqian Materials (Basel) Article Freeform surfaces are featured with superior optical and physical properties and are widely adopted in advanced optical systems. Slow tool servo (STS) ultra-precision machining is an enabling manufacturing technology for fabrication of non-rotationally symmetric surfaces. This work presents a theoretical and experimental study of surface topography generation in STS machining of freeform surfaces. To achieve the nanometric surface topography, a systematic approach for tool path generation was investigated, including tool path planning, tool geometry selection, and tool radius compensation. The tool radius compensation is performed only in one direction to ensure no high frequency motion is imposed on the non-dynamic axis. The development of the surface generation simulation allows the prediction of the surface topography under various tool and machining variables. Furthermore, it provides an important means for better understanding the surface generation mechanism without the need for costly trial and error tests. Machining and measurement experiments of a sinusoidal grid and microlens array sample validated the proposed tool path generation and demonstrated the effectiveness of the STS machining process to fabricate freeform surfaces with nanometric topography. The measurement results also show a uniform topography distribution over the entire surface and agree well with the simulated results. MDPI 2018-12-17 /pmc/articles/PMC6316587/ /pubmed/30562973 http://dx.doi.org/10.3390/ma11122566 Text en © 2018 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (http://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Li, Duo
Qiao, Zheng
Walton, Karl
Liu, Yutao
Xue, Jiadai
Wang, Bo
Jiang, Xiangqian
Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces
title Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces
title_full Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces
title_fullStr Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces
title_full_unstemmed Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces
title_short Theoretical and Experimental Investigation of Surface Topography Generation in Slow Tool Servo Ultra-Precision Machining of Freeform Surfaces
title_sort theoretical and experimental investigation of surface topography generation in slow tool servo ultra-precision machining of freeform surfaces
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6316587/
https://www.ncbi.nlm.nih.gov/pubmed/30562973
http://dx.doi.org/10.3390/ma11122566
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