Tool path generation for fabricating optical freeform surfaces by non-resonant three-dimensional elliptical vibration cutting

Abstract

Optical freeform surfaces on difficult-to-machine materials are used widely in a range of areas such as optical engineering, semiconductor and biomedical products. However, it is a challenge to achieve both a high surface quality and complex surface shape because of their tendency of being damaged in brittle fracture in the machining process. In this article, non-resonant three-dimensional elliptical vibration cutting method is proposed to obtain optical freeform surfaces of some difficult-to-machine materials, which is realised by making the diamond tool vibrate at a three-dimensional ellipse in the non-resonant manner. The elliptical motion parameters of this method can be taken active control under different machining conditions, which can make us get optimal cutting performance. Based on this new elliptical vibration cutting method, the algorithm of the tool path generation considering the tool arc radius compensation is proposed, which can avoid excess turning. The three-dimensional surface topography prediction model is established to verify the tool path. Simulation analysis on a typical optical freeform surface, toric surface, has shown that the tool path generation algorithm with the proposed elliptical vibration cutting method can envelope the toric surface, which has illustrated the validity of the proposed algorithm and technique. The tool path generation algorithm can be used to direct one to machine the optical freeform surface in the cutting experiments.

Keywords

Non-resonant three-dimensional elliptical vibration cutting optical freeform surfaces difficult-to-machine materials tool path generation simulation analysis

Get full access to this article

View all access options for this article.

References

Chiffre

Kunzmann

Peggs

. Surfaces in precision engineering, microengineering and nanotechnology. CIRP Ann Manuf Technol 2003; 52: 561–577.

Buescher NP. Live-axis turning. MS Thesis, North Carolina State University, Raleigh, NC, 2005.

Negishi N. Elliptical vibration assisted machining with single crystal diamond tools. MS Thesis, North Carolina State University, Raleigh, NC, 2003.

Liu

Rahman

. Study of ductile mode cutting in grooving of tungsten carbide with and without ultrasonic vibration assistance. Int J Adv Manuf Technol 2004; 24: 389–394.

Weck M, Winterschalden M, Pfeifer T, et al. Manufacturing of optical molds using an integrated simulation and measurement interface. In: Proceedings of the SPIE: optical fabrication, testing, and metrology, St. Etienne, France, 30 September 2003, vol. 5252.

Brecher

Lange

Merz

. NURBS based ultra-precision free-form machining. CIRP Ann Manuf Technol 2006; 55: 547–550.

Ruckman JL, Fess EM and Van Gee D. Recent advances in aspheric and conformal grinding at the center for optics manufacturing. In: Proceedings of the SPIE: optical manufacturing and testing III, Denver, CO, 18 July 1999, vol. 3782, pp. 2–10.

Tomhe Y and Lowe JA. Machining of freeform optical surfaces by slow slide servo method. Proceedings of the 18th ASPE Annual Meeting, Portland, OR, 26–31 October 2003.

Liu

Zhou

. A flexure-based long-stroke fast tool servo for diamond turning. Int J Adv Manuf Technol 2012; 59: 859–867.

10.

Evans

. Cryogenic diamond turning of stainless steel. CIRP Ann Manuf Technol 1991; 40: 571–575.

11.

Casstevens

. Diamond turning of steel in carbon saturated environments. Precis Eng 1983; 5: 9–15.

12.

Brinksmeier

Glabe

Osmera

. Ultra-precision diamond cutting of steel molds. CIRP Ann Manuf Technol 2006; 55: 551–554.

13.

Shamoto

Suzuki

Tsuchiya

. Development of 3 DOF ultrasonic vibration tool for elliptical vibration cutting of sculptured surfaces. CIRP Ann Manuf Technol 2005; 54: 321–324.

14.

Zhang

Senthil Kumar

Rahman

. Modeling of the effect of tool edge radius on surface generation in elliptical vibration cutting. Int J Adv Manuf Technol 2013; 65(1–4): 35–42.

15.

Shamoto

Suzuki

Hino

. Analysis of 3D elliptical vibration cutting with thin shear plane model. CIRP Ann Manuf Technol 2008; 57: 57–60.

16.

Brehl

Dow

. Review of vibration-assisted machining. Precis Eng 2008; 32(3): 153–172.

17.

Ahn JH, Lim HS and Son SM. Improvement of micro-machining accuracy by 2-dimensional vibration cutting. In: Proceedings of the 14th ASPE Annual Meeting, Monterey, CA, 31 October–5 November 1999, vol. 20, pp. 150–153.

18.

Brinksmeier E and Glabe R. Elliptical vibration cutting of steel with diamond tools. In: Proceedings of the 14th ASPE Annual Meeting, Monterey, CA, 31 October–5 November 1999, pp. 163–166.

19.

Brocato BC. Micromachining using EVAM (elliptical vibration assisted machining). MS Thesis, North Carolina State University, Raleigh, NC, 2005.

20.

Cerniway MA. Elliptical diamond milling: kinematics, force and tool wear. MS Thesis, North Carolina State University, Raleigh, NC, NCSU, 2002.

21.

Ehmann KF. 3D shaping with tertiary tool motion. NSF award no 0600175, 2006–2011, Northwestern University, Evanston, IL, 2006.

22.

Kim

Lee

II . Development of a programmable vibration cutting tool for diamond turning of hardened mold steels. Int J Adv Manuf Technol 2009; 40: 26–40.

23.

Kim

Loh

. An ultrasonic elliptical vibration cutting device for micro V-groove machining: kinematical analysis and micro V-groove machining characteristics. J Mater Process Technol 2007; 190: 181–188.

24.

Kim

Loh

. Machining of micro-channels and pyramid patterns using elliptical vibration cutting. Int J Adv Manuf Technol 2010; 49: 961–968.

25.

Lin JQ, Zhou XQ, Liu Q, et al. A method and device for three dimensional elliptical diamond flycutting of freeform optical surfaces by non-resonant actuation. Patent 201010282850, Changchun University of Technology, China, 2011.

26.

Zhou XQ, Liu PH, Lin JQ, et al. A device for three dimensional elliptical diamond cutting. Patent 201110343639, JiLin University, China, 2012.

27.

Stephen JL Jr. A rotary fast tool servo for diamond turning of asymmetric optics. PhD Thesis, Massachusetts Institute of Technology, Boston, MA, 1999.

28.

Cheung

Lee

. Modelling and simulation of surface topography in ultra-precision diamond turning. Proc IMechE, Part B: J Engineering Manufacture 2000; 214(6): 463–480.

29.

Zhou

Cheng

. Dynamic cutting process modelling and its impact on the generation of surface topography and texture in nano/micro cutting. Proc IMechE, Part B: J Engineering Manufacture 2009; 223(2): 247–266.

30.

Lee

Cheung

. A dynamic surface topography model for the prediction of nano-surface generation in ultra-precision machining. Int J Mech Sci 2001; 43(4): 961–991.

31.

Zhang

Fang

Wang

. Ultra-precision machining of sinusoidal surfaces using the cylindrical coordinate method. J Micromech Microeng 2009; 19: 054004–054004.

32.

. Study on prediction of surface quality in machining process. J Mater Process Technol 2008; 205(1–3): 439–450.

33.

Luo D. A constant chip-load turning approach to generating freeform optical surfaces. MS Thesis, Jilin University, 2012, pp. 17–21.