Study of the tool path generation method for an ultra-precision spherical complex surface based on a five-axis machine tool

The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spheric...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2021-08, Vol.115 (9-10), p.3251-3267
Main Authors: Xing, Tianji, Zhao, Xuesen, Cui, Zhipeng, Tan, Rongkai, Sun, Tao
Format: Article
Language:English
Subjects:
AC generators
CAE) and Design
Computer-Aided Engineering (CAD
Control equipment
Engineering
Five axis
Industrial and Production Engineering
Machine shops
Machine tools
Measuring instruments
Mechanical Engineering
Media Management
Milling machines
Original Article
Precision machining
Surface properties
Surface roughness
Turning (machining)
White light
Workpieces
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Summary:The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was proposed to generate tool paths for the machining of complex spherical surfaces based on an ultra-precise five-axis turning and milling machine with a C-Y-Z-X-B structure. Through the proposed tool path generation method, ultra-precise complex spherical surface machining was achieved. First, the complex spherical surface model was modeled and calculated, and then it was combined with the designed model to generate the tool path. Then the tool paths were generated with a numerically controlled (NC) program. Based on an ultra-precision three-coordinate measuring instrument and a white light interferometer, the machining accuracy of a workpiece surface was characterized, and the effectiveness of the tool path generation method was verified. The surface roughness of the machined workpiece was less than 90 nm. Furthermore, the surface roughness within the spherical region appeared to be less than 30 nm. The presented tool path generation method in this research produced ultra-precision spherical complex surfaces. The method could be applied to complex spherical surfaces with other characteristics.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-021-07403-w