![]() Influence of tool edge waviness on the surface profile: ( a) Comparisons between the surface roughness results with and without considering tool edge waviness ( b) tool edge waviness profile on the diamond tool. ![]() As shown in Figure 2a, the hollow square is the simulated peak-valley surface roughness R t with consideration of tool edge waviness and the straight line is the nominal peak-valley surface roughness R t = f 2/8 r ε without consideration of tool edge waviness. once adopted a high-resolution optical system to capture the image of an active tool nose profile, and their investigations show that the deviation of the tool nose profile, i.e., the tool edge waviness, alone can cause the surface roughness to vary in a large extent. Due to the existence of tool edge waviness on the cutting tool edge, deviations between the circular arc surface topography and the actual surface topography are unavoidable. Due to the state-of-the-art diamond tool fabrication technology, tool edge waviness is inevitably observed on the cutting edge of the diamond tool, which can be measured by the diamond-tool-radius-check (DTRC) system. However, the disadvantage of this kind of tool edge profile model is also obvious. Where R tew-wi( x) is the active tool edge profile in one feed rate (without consideration of the tool edge waviness) r ε is the tool corner nose radius and f is the feed rate per revolution.įor the simplification process, the Taylor formula is applied in the approximation process. On this condition, component in relation to the duplication effect of cutting edge profile can be expressed as Therefore, these three components should be taken into account in the modelling of surface profile corresponding to one tool feed as shown in Figure 1.įor the duplication effect of diamond tool edge profile, researchers originally employed the circular arc or its simplification form, i.e., the parabola expression as the tool edge profile and established the surface topography model. As revealed by the previous investigations, three main components, i.e., the duplication effect of diamond tool edge profile, material spring back and material plastic side flow, can affect the vertical distance between the highest peak and the lowest valley, i.e., the peak-valley surface roughness R t. Hence, the surface profile model in relation to one feed is the elementary unit of the total surface profile. In diamond turning, the surface topography is generated by the relative motion between the diamond tool and workpiece. Surface Profile Model Corresponding to One Tool Feed Furthermore, challenges and outlooks for the surface topography model of diamond turned components can be achieved according to the above results.Ģ.1. ![]() ![]() Finally, general models for 3D surface topography are acquired and the influencing factors in this spatial dimension, i.e., mechanical properties in relation to the work material are discussed and recommended to be integrated into the surface topography model. Afterwards, based on the surface topography in one feed rate, the 2D surface topography in the radial direction can be achieved with consideration of vibration between diamond tool and workpiece. First, the surface profile model in relation to one feed rate is analyzed and the corresponding models with the influencing factors in this spatial dimensional, such as tool edge waviness, material spring back and plastic side flow are presented. To fulfil such requirement, recent advances in the surface topography modeling of a diamond turned component is summarized and discussed in this work, which follows the modeling process of surface topography. Therefore, it is of great significance to establish an accurate surface topography model for the diamond turned components. Meanwhile, surface topography also has a direct impact on the functional performance, like the optical functions. The above controlling process technologies are applied since they can all affect the final surface topography of the diamond turned components, i.e., the surface topography is the comprehensive result of the above influencing factors. Furthermore, the ambient temperature and the surrounding environment have been strictly controlled to acquire the fine surface finish. The fluid film bearings and high-accurate numerical controller are applied on the lathes to control the relative movements between the diamond tool and the workpiece. This technology employs the ultra-sharp diamond tool mounted on the ultra-precision lathe, which is capable of achieving the nanometric surface finish and sub-micron form accuracy at the mean time. Single-point diamond turning technology is extensively employed in the advanced manufacturing process, such as the fabrication of optics components and the critical parts in the aerospace technology and clean energy. ![]()
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