Theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling
Theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling
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DOI：
10.1016/j.ijmachtools.2008.02.006
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发表时间：
2008-08
影响因子：
14
通讯作者：
M. N. Cheng;C. Cheung;W. Lee;S. To;L. Kong
中科院分区：
文献类型：
--
作者：
M. N. Cheng;C. Cheung;W. Lee;S. To;L. Kong
高质量自由曲面的制造基于超精密光栅铣削，可以直接加工具有亚微米形状精度和纳米表面光洁度的自由曲面。超精密光栅铣削是一种新兴的制造技术，用于制造表面粗糙度小于10nm、形状误差小于0.2μm的高精度、高质量零件，且无需任何额外的后处理。此外，光栅铣削表面的质量取决于切削条件和切削策略的正确选择。由于切削力学的不同，影响表面质量的工艺因素与超精密金刚石车削和常规铣削相比更加复杂，如摆距和步距。本文对超精密光栅铣削中纳米表面的生成进行了理论和实验分析。建立了预测表面粗糙度的理论模型。基于超精密光栅铣削切削条件和切削策略优化的理论模型，建立了优化系统。进行了一系列实验，结果表明，理论模型很好地预测了不同切削条件和切削策略下表面粗糙度的变化趋势。
The fabrication of high-quality freeform surfaces is based on ultra-precision raster milling, which allows direct machining of the freeform surfaces with sub-micrometric form accuracy and nanometric surface finish. Ultra-precision raster milling is an emerging manufacturing technology for the fabrication of high-precision and high-quality components with a surface roughness of less than 10nm and a form error of less than 0.2μm without the need for any additional post-processing. Moreover, the quality of a raster milled surface is based on a proper selection of cutting conditions and cutting strategies. Due to different cutting mechanics, the process factors affecting the surface quality are more complicated, as compared with ultra-precision diamond turning and conventional milling, such as swing distance and step distance. This paper presents a theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling. Theoretical models for the prediction of surface roughness are built. An optimization system is established based on the theoretical models for the optimization of cutting conditions and cutting strategy in ultra-precision raster milling. A series of experiments have conducted and the results show that the theoretical models predict well the trend of the variation of surface roughness under different cutting conditions and cutting strategies.