Investigation on the generation of the medium-frequency waviness error in flycutting based on 3D surface topography
Investigation on the generation of the medium-frequency waviness error in flycutting based on 3D surface topography
复制标题
基于3D表面形貌的飞切中频波纹度误差产生研究
DOI：
10.1007/s00170-016-9404-8
复制
发表时间：
2017-04-01
影响因子：
3.4
通讯作者：
Yao, Jin
中科院分区：
文献类型：
--
作者：
Miao, Jianguo;Yu, Deping;Yao, Jin
采用超精密单点金刚石飞切（SPDF）制备的KDP晶体在加工表面沿切割方向留下了不理想的中频波动误差，降低了KDP晶体的光学性能，限制了其在惯性约束聚变（ICF）中的性能。为了减小中频波动误差，本文提出了一种间接研究中频波动误差产生的方法。利用二维小波变换方法从三维表面形貌中提取刀尖振动，结合飞切过程的间歇切削轨迹和中频波动误差，间接提取刀尖振动。通过有限元分析和模态试验，计算了提取的刀尖振动的主频率，并与机床主轴系统的模态进行了比较。最后，在有限元分析的基础上提出了一种改进的主轴系统，并进行了原机床与改进机床的对比试验。结果表明，该方法能有效地提取出刀尖振动，由此推断产生中频波动误差的振动主要是由主轴系统的六阶模态产生的。此外，改进后的主轴系统大大提高了加工表面的质量。
Undesirable medium-frequency waviness error along the cutting direction was often left on the machined surface of KDP crystals adopting ultraprecision single-point diamond flycutting (SPDF), reducing the optical performance of KDP crystals and restricting their capability in the inertial confinement fusion (ICF). In order to reduce such medium-frequency waviness error, an indirect method for investigating the generation of the error was proposed in this paper. The tool-tip vibration was indirectly extracted by combining the intermittent cutting trajectory of the flycutting process and the medium-frequency waviness error, which was extracted from the 3D surface topography using 2D wavelet transform method. The main frequency of the extracted tool-tip vibration was calculated and compared with the modals of the machine tool spindle system, which was obtained by FEM analysis and modal test. Finally, an improved spindle system was proposed based on the FEM analysis, and contrast tests between origin and improved machine tool were carried out. Results show that the tool-tip vibration can be effectively extracted by the proposed method, which deduces that the vibration that produced the medium-frequency waviness error is mainly generated by the sixth-order modal of the spindle system. In addition, the quality of the machined surface has been greatly improved with the improved spindle system.