Monitoring a Sub-Newton Cutting Force for Ultra-Precision Machining

2000 ◽  
Vol 16 (4) ◽  
pp. 229-232 ◽  
Author(s):  
Y.H. Mu ◽  
N.P. Hung ◽  
K.A. Ngoi
Keyword(s):  
Cutting Force ◽  
Precision Machining ◽  
Ultra Precision

Study on the Effect of Rake Angle on Cutting Forces in Ultra-Precision Machining

2012 ◽  
Vol 516 ◽  
pp. 551-556
Author(s):  
Thanh Hung Duong ◽  
Kim Huyn Chul ◽  
Lee Dong Yoon
Keyword(s):  
Theoretical Analysis ◽  
Cutting Force ◽  
Electroless Nickel ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Precision Machining ◽  
Reported Study ◽  
Ultra Precision ◽  
The Relationship ◽  
Cutting Speeds

In recent years, there have been many studies concerning the effect of cutting parameters and tool parameters on the ultra precision machining of electroless nickel. However, there is no known reported study on the relationship between the cutting force and tool rake angle in ultra precision machining of electroless nickel. The objective of this study is to compare and investigate the cutting force with various rake angles for micro machining electroless nickel work pieces by theoretical analysis and experiment. Diamond tools with rake angles of-10o, 0o and 10o were used in the experiment. According to theoretical analysis, the tool with a 10o rake angle induces the smallest cutting force. However, the experiment showed that the tool with zero rake angle always gave us the smallest cutting force for all cutting speeds, cutting depths and pattern pitches.

scholarly journals Design and Manufacturing of a High-Sensitivity Cutting Force Sensor Based on AlSiCO Ceramic

Micromachines ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 63
Author(s):  
Taobo Gong ◽  
You Zhao ◽  
Yulong Zhao ◽  
Lukang Wang ◽  
Yu Yang ◽  
...  
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
High Sensitivity ◽  
Force Sensor ◽  
High Price ◽  
Precision Machining ◽  
Force Sensors ◽  
Machining Accuracy ◽  
Status Monitoring ◽  
Ultra Precision

On-line cutting force measurement is an effective way to monitor processing quality, improve processing accuracy, and protect the tool. In high-speed and ultra-precision machining, status monitoring is particularly necessary to ensure machining accuracy. However, the cutting force is very small in high speed and ultra-precision machining. Therefore, high-sensitivity cutting force sensors are needed. Current commercial cutting force sensors have defects such as large volume, low compatibility, and high price. In particular, the sensitivity of cutting force sensor needs to be improved for high-speed and ultra-precision machining status monitoring. This paper provides a possible solution by embedding the sensor in the tool and selecting sensitive materials with high piezoresistive coefficient. In this paper, the structural design of the sensor and the fabrication of the sensitive material SiAlCO ceramic are carried out, and then the sensor is packaged and tested. The test results show that the cutting force sensor’s sensitivity was as high as 219.38 mV/N, which is a feasible way to improve cutting force sensor’s compatibility and sensitivity.

Research on Influence of the Material Anisotropy to the Surface Quality during SPDT Machining of Crystal KDP

2006 ◽  
Vol 532-533 ◽  
pp. 209-212 ◽  
Author(s):  
Ming Jun Chen ◽  
Ying Chun Liang ◽  
Jing He Wang ◽  
Xin Zhou Zhang
Keyword(s):  
Theoretical Analysis ◽  
Machine Tool ◽  
Cutting Force ◽  
Surface Quality ◽  
Smooth Surface ◽  
Precision Machining ◽  
Optimal Parameters ◽  
Material Anisotropy ◽  
Crystal Anisotropy ◽  
Ultra Precision

A theoretical analysis on the variation regularity of cutting force caused by the material anisotropy with different orientation of KDP is analyzed firstly; influence and regularity of the variation are obtained. Analysis result shows that the crystal anisotropy of KDP is an important factor in obtaining the super-smooth surface. Then experiments are realized on the machine tool, results afford the variation regularity of cutting force caused by the anisotropy with different orientation of KDP, which certifies the correctness of this theoretical analysis. For ultra-precision machining of the KDP at large negative rake diamond cutter (-45°) and the optimal parameters, the super-smooth surface (rms is 8.702 nm, Ra is 6.895 nm) can be obtained on the plane (001).

scholarly journals A Self-Established “Machining-Measurement-Evaluation” Integrated Platform for Taper Cutting Experiments and Applications

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 929
Author(s):  
Xudong Yang ◽  
Zexiao Li ◽  
Linlin Zhu ◽  
Yuchu Dong ◽  
Lei Liu ◽  
...  
Keyword(s):  
Three Dimensional ◽  
Precision Machining ◽  
Two Dimensional ◽  
Dimensional Image ◽  
Two Dimensional Image ◽  
Integrated Platform ◽  
Hard And Brittle Materials ◽  
Ultra Precision ◽  
Cutting Experiments

Taper-cutting experiments are important means of exploring the nano-cutting mechanisms of hard and brittle materials. Under current cutting conditions, the brittle-ductile transition depth (BDTD) of a material can be obtained through a taper-cutting experiment. However, taper-cutting experiments mostly rely on ultra-precision machining tools, which have a low efficiency and high cost, and it is thus difficult to realize in situ measurements. For taper-cut surfaces, three-dimensional microscopy and two-dimensional image calculation methods are generally used to obtain the BDTDs of materials, which have a great degree of subjectivity, leading to low accuracy. In this paper, an integrated system-processing platform is designed and established in order to realize the processing, measurement, and evaluation of taper-cutting experiments on hard and brittle materials. A spectral confocal sensor is introduced to assist in the assembly and adjustment of the workpiece. This system can directly perform taper-cutting experiments rather than using ultra-precision machining tools, and a small white light interference sensor is integrated for in situ measurement of the three-dimensional topography of the cutting surface. A method for the calculation of BDTD is proposed in order to accurately obtain the BDTDs of materials based on three-dimensional data that are supplemented by two-dimensional images. The results show that the cutting effects of the integrated platform on taper cutting have a strong agreement with the effects of ultra-precision machining tools, thus proving the stability and reliability of the integrated platform. The two-dimensional image measurement results show that the proposed measurement method is accurate and feasible. Finally, microstructure arrays were fabricated on the integrated platform as a typical case of a high-precision application.

scholarly journals An Investigation of the Cutting Strategy for the Machining of Polar Microstructures Used in Ultra-Precision Machining Optical Precision Measurement

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 755
Author(s):  
Chen-Yang Zhao ◽  
Chi-Fai Cheung ◽  
Wen-Peng Fu
Keyword(s):  
Precision Measurement ◽  
Detection Algorithm ◽  
Surface Generation ◽  
Precision Machining ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ultra Precision ◽  
Transition Points ◽  
Cutting Strategy

In this paper, an investigation of cutting strategy is presented for the optimization of machining parameters in the ultra-precision machining of polar microstructures, which are used for optical precision measurement. The critical machining parameters affecting the surface generation and surface quality in the machining of polar microstructures are studied. Hence, the critical ranges of machining parameters have been determined through a series of cutting simulations, as well as cutting experiments. First of all, the influence of field of view (FOV) is investigated. After that, theoretical modeling of polar microstructures is built to generate the simulated surface topography of polar microstructures. A feature point detection algorithm is built for image processing of polar microstructures. Hence, an experimental investigation of the influence of cutting tool geometry, depth of cut, and groove spacing of polar microstructures was conducted. There are transition points from which the patterns of surface generation of polar microstructures vary with the machining parameters. The optimization of machining parameters and determination of the optimized cutting strategy are undertaken in the ultra-precision machining of polar microstructures.

Study on Ultra-Precision Ball Surface Floating Polishing Kinematics Mechanism

2006 ◽  
Vol 532-533 ◽  
pp. 109-112
Author(s):  
Xun Lv ◽  
Ju Long Yuan ◽  
Dong Hui Wen ◽  
Qian Fa Deng ◽  
Fei Yan Lou
Keyword(s):  
Chemical Conversion ◽  
Processing Parameters ◽  
Precision Machining ◽  
High Tech ◽  
National Defense ◽  
Ball Surface ◽  
Angular Velocities ◽  
Ultra Precision ◽  
Relationship Of ◽  
The Mathematical Model

The high precision balls are requested in national defense, astronautics and high-tech commercial domain urgently. Conventional precision machining methods are sensitive to uniformity of abrasives and machining environment. After precision machining, there are easily to produce thick damaged layer on the ball surface because of machining stress and chemical conversion. On the basis of the floating polishing mechanism, a new scatheless ultra-precision polishing method of ball surface can solve the problems of abrasives uniformity effectively and damaged layer. In order to ensure that the new polishing method polishes ball surface equally, the appropriate angular velocities of the ball should be selected. This paper sets up the mathematical model about the motion of ball. By analyzing and simulating the relationship of the angular velocities, the best processing parameters are acquired.

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