Ultra-precision milling with multiple diamond tools

使用多个金刚石刀具进行超精密铣削时，需要能够进行明确的刀具调整，以便将所有参与切削过程的刀具调整到一个共同的半径。在研究单位FOR 1845超精密高性能切削的子项目中，结果表明，热-机械致动器可以达到限定的热伸长状态，微米，精度在纳米范围内。因此，在第一个资助阶段结束时，这一概念被转移到一个原型金刚石工具保持器上，该工具将能够执行基本的飞切操作。第二个资助阶段的重点是在真实的切割条件下应用这一原型工具保持器。总体目标将是系统的和方法学的确定系统的边界条件的背景下，产生光学功能表面与多切削刀具。第一步将是确定的方法来测量金刚石工具的径向位移。这是在切削之前评估刀具保持器的实际状况以及为执行器生成所需设定值所必需的。随后，将该刀具保持器应用于超精密铣削实验，以获得加工过程的反馈。这些数据将用于验证第一个资助阶段生成的致动器的理论模型，并评估致动器在实际切削条件下的性能。由于金刚石加工中切削刃的定义位移为过程控制提供了新的可能性，因此在拟议的资助阶段也将对特定方面进行研究。这包括通过致动器的不对称加热在任意方向上的工具位移的适用性，以及将该技术用于超精密平衡目的。在第二个资助阶段结束时，热机械致动器以及在FOR 1845中开发的其他组件将被集成到演示平台中，并对其综合性能进行评估。这将通过进行超精密铣削操作来完成，包括多个金刚石工具，高主轴速度和进给速度以及控制系统中基于模型的补偿策略，并将其与传统的超精密铣削工艺进行比较。

Ultra-precision milling with multiple diamond tools requires the possibility of a defined tool adjustment for aligning all tools engaged in the cutting process to a common radius.In this subproject of the research unit FOR1845 Ultra-precision high performance cutting, it was shown that a thermo-mechanical actuator can be brought to a state of defined thermal elongation that allows for a precise displacement of a diamond tool across several micrometers with a precision in the nanometer range. Thus, the concept was transferred to a prototype diamond tool holder that will be able to perform basic fly-cutting operations at the end of the first funding phase.The second funding phase focusses on the application of this prototype tool holder under real cutting conditions. The overarching goal will be the systematic and methodological determination of the systems boundary conditions in the context of generating optical functional surfaces with multiple cutting tools.The first step will be the identification of the methodology for measuring the radial displacement of the diamond tools. This is required for assessing the actual condition of the tool holder prior to cutting and to generate the required set values for the actuator. Subsequently, the tool holder will be applied in ultra-precision milling experiments, in order to obtain a feedback from the machining process. This data will be used to verify the theoretical models of the actuator that were generated in the first funding phase and to assess the performance of the actuator under realistic cutting conditions.As the defined displacement of the cutting edges in diamond machining offers new possibilities for process control, specific aspects will be examined in the proposed funding phase as well. This includes the applicability of a tool displacement in arbitrary directions by asymmetric heating of the actuator as well as using this technique for ultra-precision balancing purposes. At the end of the second funding phase, the thermo-mechanical actuator, among other components that are developed within the FOR1845, will be integrated into a demonstration platform and evaluated for their combined performance. This will be done by conducting ultra-precision milling operations including multiple diamond tools, high spindle speed and feed velocity as well as model-based compensation strategies in the control system and comparing them with conventional ultra-precision milling processes.