Ultra-precision milling with multiple diamond tools

使用多个金刚石刀具的超精密铣削需要确定的刀具调整的可能性，以便将所有参与切割过程的刀具对齐到公共半径。在研究单位FOR1845超精密高性能切割的这个子项目中，证明了热机械执行器可以被带到定义的热伸长状态，允许钻石刀具以纳米范围内的精度在几个微米范围内精确地移动。因此，这一概念被转移到一个原型钻石刀架，它将能够在第一个资助阶段结束时执行基本的飞切操作。第二个资助阶段侧重于这种原型刀具支架在实际切割条件下的应用。总体目标将是在用多种切割工具生成光学功能表面的背景下系统和方法地确定系统边界条件。第一步是确定测量金刚石工具径向位移的方法。这对于在切割之前评估刀架的实际状况以及为执行机构生成所需的设定值是必需的。随后，将刀具夹具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在第一个资助阶段生成的执行器的理论模型，并评估执行器在现实切割条件下的性能。由于钻石加工中定义的刃口位移为过程控制提供了新的可能性，因此还将在拟议的资助阶段检查具体方面。这包括通过执行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，热机械执行器以及在FOR1845内开发的其他部件将被集成到一个演示平台中，并对其综合性能进行评估。这将通过在控制系统中执行包括多个金刚石刀具、高主轴速度和进给速度以及基于模型的补偿策略的超精密铣削操作来实现，并将它们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.