超精密飞刀铣削刀具磨损及工件表面特征创成的在线评估新方法研究

针对超精密飞刀铣削中刀具磨损及工件表面特征创成在线评估研究工作中存在的诸多关键问题，本课题提出一种基于切屑形貌的刀具磨损及工件表面特征创成的在线评估新方法，其主要特征在于：根据超精密飞刀铣削的间断性切削机制以及刀具磨损特征、切屑形貌特征和工件表面形貌特征之间的几何关系，利用切屑形貌实现刀具磨损及工件表面特征创成的在线评估。本课题结合理论研究与实验分析，致力于实现基于切屑形貌的刀具磨损特征在线评估；致力于实现基于切屑形貌的工件表面形貌及粗糙度值在线预测；致力于实现刀具磨损特征及工件表面特征创成辨识过程中的误差分析与精度矫正。通过本课题的研究，有助于促进微切削机理和刀具磨损下切屑形成的理论研究和技术突破，实现超精密飞刀铣削中刀具磨损及工件表面特征创成的在线精确辨识。本课题的研究将为提高加工效率、降低加工成本以及拓展金刚石刀具在光学微结构加工中的应用范围提供理论与技术支撑。

Aiming at many key problems existed in the research of online evaluation of tool wear and its effects on machined surface quality in ultra-precision raster milling (UPRM), this project proposed a novel online evaluation method for tool wear and its effects on machined surface quality based on cutting chip morphology with the main feature that who is realized based on the intermittent cutting mechanism of UPRM and the closed correlations between tool wear characteristics, chip morphology and machined surface topography. This project combines both theoretical research and experimental investigation, committed to the online evaluation of tool wear by using cutting chip morphology, committed to the online prediction of the machined surface topography and roughness under tool wear by using cutting chip morphology, committed to the error analysis and compensation in the identification of tool wear characteristics and their effects on machined surface quality. The study in this project contributes to the theoretical research and technology breakthrough in the micro-cutting mechanism and the chip formation under tool wear, contributes to the precise online identification of tool wear characteristics and their effects on machined surface quality in UPRM. The research in this project will provide theoretical and technical support in enhancing the cutting efficiency, reducing the cutting cost of UPRM and widening the application of UPRM on the fabrication of optical micro-structures.