Simulation and experiment on surface topography of complex surface in single point diamond turning based on determined tool path

Abstract

Surface topography is an important element that reflects the machining quality of workpieces and the functional performance of components. To avoid expensive cutting experiments, forecasting the surface topography before actual machining is necessary. Surface topography of diamond turned surfaces is directly affected by generated tool path in ultraprecision single point diamond turning (SPDT). In this study, a novel surface topography modeling method was presented. The planned tool path based on active machining precision control was considered in this method. Simulation and experiment of an umbrella surface diamond turning were conducted to testify the usability of the proposed model. Through comparing the simulation and experimental data of surface topography and machining error, the results showed that the proposed model can be applied to forecast the surface topography and machining error in SPDT using the generated tool path.

This is a preview of subscription content, access via your institution.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

References

  1. 1.

    He CL, Zong WJ (2019) Influencing factors and theoretical models for the surface topography in diamond turning process: a review. Micromachines 10(5)

  2. 2.

    He CL, Zong WJ, Cao ZM, Sun T (2015) Theoretical and empirical coupled modeling on the surface roughness in diamond turning. Mater Des 82:216–222

    Article  Google Scholar 

  3. 3.

    Wang ZF, Zhang JJ, Zhang JG, Li G, Zhang HJ, ul Hassan H, Hartmaier A, Yan YD, Sun T (2020) Towards an understanding of grain boundary step in diamond cutting of polycrystalline copper. J Mater Process Technol 276:116400

    Article  Google Scholar 

  4. 4.

    Yuan W, Chan CY, Li LH, Lee WB (2017) Investigation of the surface profile along the cutting trajectory and its correlation with cutting forces in single point diamond turning. Int J Adv Manuf Technol 89(5-8):1327–1338

    Article  Google Scholar 

  5. 5.

    Sung AN, Loh WP, Ratnam MM (2017) Simulation approach for surface roughness interval prediction in finish turning. Int J Simul Model 89(5-8):1327–1338

    Google Scholar 

  6. 6.

    Huang CY, Liang RG (2017) Modeling of surface topography on diamond-turned spherical and freeform surfaces. Appl Opt 56(15):4466–4473

    Article  Google Scholar 

  7. 7.

    He CL, Zong WJ, Xue CX, Sun T (2018) An accurate 3D surface topography model for single-point diamond turning. Int J Mach Tool Manu 134:42–68

    Article  Google Scholar 

  8. 8.

    Chen JY, Zhao QL (2015) A model for predicting surface roughness in single-point diamond turning. Measurement. 69:20–30

    Article  Google Scholar 

  9. 9.

    Yang J, Wang XS, Kang M (2018) Finite element simulation of surface roughness in diamond turning of spherical surfaces. J Manuf Process 31:768–775

    Article  Google Scholar 

  10. 10.

    Zhang QL, Guo N, Chen Y, Fu YC, Zhao QL (2019) Simulation and experimental study on the surface generation mechanism of Cu alloys in ultra-precision diamond turning. Micromachines 10(9)

  11. 11.

    Li D, Qiao Z, Walton K, Liu YT, Xue JD, Wang B, Jiang XQ (2018) Theoretical and experimental investigation of surface topography generation in slow tool servo ultra- precision machining of freeform surfaces. Materials 11(12)

  12. 12.

    Cai HB, Shi GQ (2019) Finite element simulation of surface roughness in diamond turning of spherical surfaces. Exp Tech 43(5):561–569

    Article  Google Scholar 

  13. 13.

    Zhang L, Naples NJ, Zhou WC, Yi AY (2019) Fabrication of infrared hexagonal microlens array by novel diamond turning method and precision glass molding. J Micromech Microeng 29(6)

  14. 14.

    Ji SJ, Li JF, Zhao J, Feng M, Sun CR, Dai HD (2018) Ultra-precision machining of a compound sinusoidal grid surface based on slow tool servo. Materials 11(6)

  15. 15.

    Ning PX, Zhao J, Ji SJ, Li JJ, Dai HD (2020) Ultra-precision machining of a large amplitude umbrella surface based on slow tool servo. Int J Precis Eng Manuf 21:1999–2010

    Article  Google Scholar 

Download references

Funding

This work is supported by Key R&D Projects of the Ministry of Science and Technology of China (Grant Nos. 2017YFA0701200 and 2018YFB1107600), National Natural Science Foundation of China (Grant No. 51775237), and Graduate Innovation Fund of Jilin University (Grant No. 101832020CX122).

Author information

Affiliations

Authors

Contributions

P.N., S.J., J.Z., and J.L. contributed to the conception of the study; P.N., S.J., and J.L. studied the surface topography prediction model; P.N., J.Z, and J.L. performed a surface topography simulation of an umbra surface to verify the proposed model; H.D. and J.L. performed the machining experiment and were in charge of data management; P.N., S.J., and J.L. analyzed the experimental results and concluded the whole work; P.N. wrote the original draft; S.J. reviewed and edited the manuscript; J.Z. supervised all works; The supporting projects for this study were administered by P.N., S.J., J.Z., and H.D.

Corresponding authors

Correspondence to Ji Zhao or Shijun Ji.

Ethics declarations

Ethics approval

The research did not involve human participants or animals.

Consent to participate

The research did not involve human participants or animals.

Consent to publish

We would like to submit the enclosed manuscript entitled “Simulation and experiment on surface topography of complex surface in single point diamond turning based on determined tool path” to The International Journal of Advanced Manufacturing Technology to be considered for publication. No conflict of interest exits in the submission of this manuscript, and manuscript is approved by all authors for publication. We would like to declare on behalf of my coauthors that the work described was original research that has not been published previously, and not under consideration for publication elsewhere, in whole or in part. All the authors listed have approved the manuscript that is enclosed.

Competing interests

The authors declare no conflict of interest.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Appendix

Appendix

Since i = 500, j = 500, Lx = Ly = 8mm, dx = dy = 0.01mm, based on Eq. (1) the XY coordinates can be calculated as A.1:

$$ \left\{\begin{array}{c}{X}_k=500\times 0.01-\frac{8}{2}=1\\ {}{Y}_k=500\times 0.01-\frac{8}{2}=1\end{array}\right. $$
(A.1)

According to Eq. (2), the polar coordinates of Pk is given by A.2:

$$ \left\{\begin{array}{c}{\rho}_k=\sqrt{1^2+{1}^2}=\sqrt{2}\\ {}{\theta}_k=\arctan \left(\frac{1}{1}\right)=\frac{\pi }{4}\end{array}\right. $$
(A.2)

As presented in Fig. 1, to calculate the Z coordinate of Pk, the CCPs closest to Pk on two adjacent circles of the planned tool path should be determined firstly. Since f = 0.0629 mm/r, on the basis of Eq. (3), the number of entire cycle Nt before point Pk can be obtained by A.3:

$$ {N}_t=\left\lfloor \sqrt{2}/0.0629\right\rfloor =22 $$
(A.3)

In the light of Eq. (4), the angle coordinate θkl of point Pk can be indicated as A.4:

$$ {\theta}_{kl}=\frac{\pi }{4}+22\times 2\pi =139.0155 $$
(A.4)

The planned tool path of the umbrella surface workpiece machining is given in Fig. 3. According to the coordinates of Pk (ρk, θkl) calculated above, the coordinates of CCPs that closest to Pk were determined as Pl1(1.4047, 139.0058, −0.0189) and Pl2(1.4680, 145.2767,   − 0.0216). To calculate the Z coordinate of Pk, it is necessary to ascertain the cutting positions on the planned tool path that enables the tool to cut to point Pk. As shown in Fig. 1, the cutting position may be between two adjacent CCPs, so the cutting sections [Pl1,Pl1 + 1] and [Pl2,Pl2 + 1] should be further confirmed. It can be obtained from Fig. 3 that the coordinates of the other CCPs in the cutting sections [Pl1,Pl1 + 1] and [Pl2,Pl2 + 1] are Pl1 + 1(1.4052,  139.0591,   − 0.0116) and Pl2 + 1(1.4686,  145.3286,   − 0.0140). Because there is a small straight line between the two adjacent CCPs on the planned tool path, the coordinates of the cutting positions Pkl1 and Pkl2 can be calculated by the interpolation method expressed in Eq. (5), as shown in A.5:

$$ \left\{\begin{array}{c}{\theta}_{kl1}=139.0155\\ {}{\rho}_{kl1}=1.4047-\left[\left(1.4047-1.4052\right)\times \frac{139.0058-139.0155}{139.0058-139.0591}\right]=1.3984\\ {}{z}_{kl1}=-0.0189-\left[\left(-0.0189+0.0116\right)\times \frac{139.0058-139.0155}{139.0058-139.0591}\right]=-0.0176\end{array}\right. $$
$$ \left\{\begin{array}{c}{\theta}_{kl2}=139.0155\\ {}{\rho}_{kl2}=1.4680-\left[\left(1.4680-1.4686\right)\times \frac{145.2767-139.0155}{145.2767-145.32861}\right]=1.3984\\ {}{z}_{kl2}=-0.0216-\left[\left(-0.0216+0.0140\right)\times \frac{145.2767-139.0155}{145.2767-145.32861}\right]=-0.0184\end{array}\right. $$
(A.5)

The coordinates of CLPs corresponding to the cutting position can be deduced and calculated as Pkl1 ′ (1.3984, 139.0155, 0.4884) and Pkl2 ′ (1.4619, 139.0155, 0.4876) using the same way. According to Eq. (6), the residual heights zl1 and zl2 generated at point Pk when the tool was cutting at those two cutting positions can be calculated by A.6:

$$ {z}_{l1}=0.4884-\sqrt{0.506^2-{\left(\sqrt{2}-1.3984\right)}^2}=-0.0174 $$
$$ {z}_{l2}=0.4876-\sqrt{0.506^2-{\left(\sqrt{2}-1.4619\right)}^2}=-0.0161 $$
(A.6)

From Eq. (7), the minimum value of the two residual heights was z coordinate of the grid point Pk, as given by A.7:

$$ {z}_k=\min \left(-0.0174,-0.0161\right)=-0.0174 $$
(A.7)

After the above calculation, the coordinate of grid point Pk was obtained as (1, 1, −0.0174).

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Ning, P., Zhao, J., Ji, S. et al. Simulation and experiment on surface topography of complex surface in single point diamond turning based on determined tool path. Int J Adv Manuf Technol 113, 2555–2562 (2021). https://doi.org/10.1007/s00170-021-06671-w

Download citation

Keywords

  • Surface topography simulation
  • Tool path
  • Slow tool servo (STS)
  • Single point diamond turning (SPDT)
  • Machining error