Proceedings of the
9th International Conference of Asian Society for Precision Engineering and Nanotechnology (ASPEN2022)
15 – 18 November 2022, Singapore

Investigation of Segment Turning Process based on Single-amplitude-frequency Criterion for Complicated Multi-Scale Surface Structure

Xiao Lua, Chi Fai Cheung, Chunjin Wang, Canbin Zhang and Lai Ting Ho

State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, China


With the continuously promotion of NC machining technologies, the diamond turning can be adaptively utilized for the manufacturing of multi-scale functional microstructure, which has been increasingly applied in many fields currently. However, the complicated geometrical features due to the multi-scale structure leads to huge challenge for the dynamic capability of machine tool. Specially, focusing on the multi-scale structure, the machining error is dramatically enlarged when cutting along the global-continuous toolpath. In this paper, an investigation is presented for sub-regional toolpath and vacant-path planning in segment turning based on single-amplitude-frequency criterion considering integrated geometrical-physical factors for complicated multi-scale surface structure. Based on the macroscopic analysis from the established kinematic and dynamic model for slow tool servo (STS) turning machine tool, the multivariate mapping relation between microstructure geometry, amplitude-frequency characteristic of axes of machine tool and designed machining trajectory is studied theoretically. The influencing mechanism from amplitude-frequency characteristics to dynamic capability is investigated. Hence, the surface segmentation according to the local amplitude-frequency characteristic of multi-scale structure is carried out and the relating segment turning with multiple feeding processing is planned. Finally, the sub-regional processing is accomplished by STS turning for multi-scale surface structure by stitching toolpath/vacant-path corresponded to the local structure with single amplitude-frequency characteristic so as to adapt to the dynamic capability of machine tool and ameliorate the machining quality, where both the theoretical and experimental investigations have supported the expectation. This method can minimize the influence of the dynamic capability limitation of the machine tool on the machining quality by modifying the toolpath on the basis of the existing machining conditions.

Keywords: Multi-Scale Surface Structure, Amplitude-frequency Characteristic, Dynamic Capability, Ultra-precision machining

Download PDF