1、Study on the Technology of Slow Tool Servo Ultra-Precision Diamond Turning for Complex Optical Surface Journal of Manufacturing Systems Vol. 16/No. 1 1997 The inclusion of freeform elements in an optical system provides opportunities for numerous improvements in performance. However, designers are r
2、eluctant to utilize freeform surfaces due to the complexity and uncertainty of their fabrication. Single diamond turning is a novel machining process capable of generating freeform optical surfaces or rotational non-symmetric surfaces at high levels of accuracy. In order to achieve good results with
3、 this technology some key parameters need to be satisfied. These parameters include tool geometry, tool path generation, tool radius correction,and servo system performance. The servo capacity of slow-tool-servo machine is analysed, and a method to determine tool geometry parameter based on surface
4、analysis is developed. The methods of tool radius compensation and tool path generation to ensure the stability of X-axis are researched. Experiment results show that slow-tool-servo machining technology can be used in preparation of optical free form surfaces element Slow Tool Servo and Fast Tool S
5、ervo are the develop faster ultra-precision processing technology in the rencent , the two kind of technology can significantly improve the microstructure are arrays and free surface optical device processing efficiency. Slow Tool Servo is on the lathe spindle and turning the Z axis are control, mak
6、e the spindle into position controllable C axis, machine Tool of the X and Z, C three axis in the space form the cylindrical coordinate system, at the same time, high performance and high programming of CNC system will resolution complex face form components of the three-dimensional cartesian coordi
7、nate into polar coordinates, and all moving axis to send interpolation into to instructions, precise coordination shaft and the relative motion of the cutting Tool, and to realize the complex face form of turning machining parts. Slow knife servo turning the Z axis X axis and often also make sine re
8、ciprocating motion, requires multi-axis interpolation linkage. Therefore, in the process of parts required before more face form the analysis of the coordination between the shaft, then determines the tool path and cutting tools compensation. In addition, slow sword by machine tool servo slide inert
9、ia and response speed and motor to influence is bigger, machine tool dynamic response speed is low, suitable for processing face form and larger complex for optical device. Fast Tool Servo turning and slow knife Servo differ in that will be processing complex shape face turning into shape face and f
10、orm the microstructure of the surface, and then will both stack. The X axis and Z axis to realize the turn into shape trajectory, lathe spindle of only position detection do not track control. With installed in the Z axis but independent of CNC outside the system of redundancy axes to drive the cutt
11、ing tools, complete turning the surface microstructure form the Z axis movement. The processing method has high frequency, high stiffness, the characteristics of high precision. Diamond tools in piezoelectric actuators can be under the reciprocating movement of the Z axis. Control system in real-tim
12、e acquisition spindle Angle signal, and on the basis of real-time sends out of control, real-time control tool to micro into, so as to realize the cutting tool tracking face form the rise and fall of the change. A sharp sword servo in processing only for parts before face form for accurate calculati
13、on, generation of the components of the form that can characterize data files. In addition, a sharp sword servo system frequency response high, the movement of the trip with only a few mm, more suitable for processing face form mutation or discontinuous, limited schedule tiny structures within. Free
14、form surfaces can be used in optical systems to achieve novel functions, improve performances, reduce size, and decrease the cost of various products. Therefore, optical freeform surfaces find applications in the fields of optics, medicine, fiber communication, life science, aerospace etc. Freeform
15、optics has become the key element of quantitative light technology, which is becoming increasingly important in various fields. However, designers are reluctant to utilize freeform surfaces due to the complexity and uncertainty of their fabrication. Slow Slide Servo is a novel machining process capa
16、ble of generating freeform optical surfaces or rotationally non-symmetric surfaces at high levels of accuracy. In order to achieve high accuracy optical complex surface by using Slow Tool Servo turning, the major research efforts include the following points. 1. The theory of Slow Tool Servo turning
17、 and key technologies. A systematic introduction of the theory of Slow Tool Servo turning is first given by analyzing machine architecture and movements. By comparing with some other conventional technologies, the key technologies are high dynamic feed drive system, advanced interpolation technology
18、 and position control spindle technology. Then, the research emphasis on the performance of feed drive system and curve interpolation algorithm. Several aspects are discussed to improve the motion accuracy and control performance of feed drive system. PVT interpolation algorithm is introduced to Slo
19、w Tool Servo turning to overcome inherit drawback of conventional interpolation algorithm. In order to estimate the machining scope and accuracy, study on the machining capacity of Slow Tool Servo turning. 2. The design theory of tool geometry parameters in ultra-precision Slow Tool Servo turning co
20、mplex optical surface. Based on the requirements of slow tool servo, two types of tool are designed and analytic geometry models of cutting edge are built. A geometrical approach is introduced to formulate the relationship between tool tip and complex surface. By virtue of surface analytic method, t
21、he problem is solved efficiently, combined with the NURBS representation of complex surface. Experiments are carried out to validate solving algorithm. In addition, the relation models between tool shape and roughness, optical property and materials are built. 3. The programming theory of tool path in ultra-precision Slow Tool Servo
