Modelling and simulation of freeform surface generation in ultra-precision raster milling
Modelling and simulation of freeform surface generation in ultra-precision raster milling
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DOI：
10.1243/09544054jem548
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发表时间：
2006-11
期刊：
影响因子：
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通讯作者：
C. Cheung;L. Kong;W. Lee;S. To
中科院分区：
文献类型：
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作者：
C. Cheung;L. Kong;W. Lee;S. To
摘要 光学自由曲面是大规模表面拓扑，其形状通常具有非旋转对称性、亚微米形状精度和纳米表面光洁度。由于几何复杂性，超精密自由曲面超精密光栅铣削中形状精度的预测比传统加工更加困难。如今，亚微米形状精度的实现仍然在很大程度上取决于机器操作员通过昂贵的试错方法的经验和技能。本文提出了一种基于模型的仿真系统，用于预测光学自由曲面超精密光栅铣削中的形状精度。该系统考虑了切削力学、切削策略和切削过程的运动学。对该系统进行了实验验证，预测结果与实验结果吻合良好。基于模型的仿真系统的成功开发可以确定最佳切削参数和切削策略，而无需进行大量且昂贵的试错切削测试。
Abstract Optical freeform surfaces are large-scale surface topologies with shapes generally possessing non-rotational symmetry with submicrometric form accuracy and nanometric surface finish. Due to the geometrical complexities, the prediction of form accuracy in ultraprecision raster milling of ultra-precision freeform surfaces is more difficult than conventional machining. Nowadays, the achievement of submicrometre form accuracy still depends largely on the experience and skills of the machine operators through an expensive trial-and-error approach. This paper presents a model-based simulation system for the prediction of form accuracy in ultra-precision raster milling of optical freeform surfaces. The system takes into account the cutting mechanics, cutting strategy, and the kinematics of the cutting process. Experimental work has been undertaken to verify the system and the predicted results agree well with the experimental results. The successful development of the model-based simulation system allows the optimum cutting parameters and cutting strategies to be determined without the need to conduct massive and costly trial-and-error cutting tests.