scholarly journals Effects of Machining Errors on Optical Performance of Optical Aspheric Components in Ultra-Precision Diamond Turning

Micromachines ◽  
2020 ◽  
Vol 11 (3) ◽  
pp. 331
Author(s):  
Yingchun Li ◽  
Yaoyao Zhang ◽  
Jieqiong Lin ◽  
Allen Yi ◽  
Xiaoqin Zhou
Keyword(s):  
Diamond Turning ◽  
Machining Accuracy ◽  
Aspheric Surface ◽  
Optical Performance ◽  
Machining Error ◽  
Optical Components ◽  
Optical Lens ◽  
Machining Errors ◽  
Ultra Precision ◽  
Multi Body

Optical aspheric components are inevitably affected by various disturbances during their precision machining, which reduces the actual machining accuracy and affects the optical performance of components. In this paper, based on the theory of multi-body system, we established a machining error model for optical aspheric surface machined by fast tool servo turning and analyzed the effect of the geometric errors on the machining accuracy of optical aspheric surface. We used the method of ray tracing to analyze the effect of the surface form distortion caused by the machining error on the optical performance, and identified the main machining errors according to the optical performance. Finally, the aspheric surface was successfully applied to the design of optical lens components for an aerial camera. Our research has a certain guiding significance for the identification and compensation of machining errors of optical components.

A Data-Driven Machining Error Analysis Method for Finish Machining of Assembly Interfaces of Large-Scale Components

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
Wei Fan ◽  
Lianyu Zheng ◽  
Wei Ji ◽  
Xun Xu ◽  
Lihui Wang ◽  
...  
Keyword(s):  
Error Analysis ◽  
Large Scale ◽  
Tool Path ◽  
Cutting Parameters ◽  
Pso Algorithm ◽  
Data Driven ◽  
Machining Accuracy ◽  
Machining Error ◽  
Spatial Statistical Analysis ◽  
Machining Errors

Abstract To guarantee the final assembly quality of the large-scale components, the assembly interfaces of large components need to be finish-machined on site. Such assembly interfaces are often in low-stiffness structure and made of difficult-to-cut materials, which makes it hard to fulfill machining tolerance. To solve this issue, a data-driven adaptive machining error analysis and compensation method is proposed based on on-machine measurement. Within this context, an initial definite plane is fitted via an improved robust iterating least-squares plane-fitting method based on the spatial statistical analysis result of machining errors of the key measurement points. Then, the parameters of the definite plane are solved by a simulated annealing-particle swarm optimization (SA-PSO) algorithm to determine the optimal definite plane; it effectively decomposes the machining error into systematic error and process error. To reduce these errors, compensation methods, tool-path adjustment method, and an optimized group of cutting parameters are proposed. The proposed method is validated by a set of cutting tests of an assembly interface of a large-scale aircraft vertical tail. The results indicate that the machining errors are successfully separated, and each type of error has been reduced by the proposed method. A 0.017 mm machining accuracy of the wall-thickness of the assembly interface has been achieved, well fulfilling the requirement of 0.05 mm tolerance.

Effect of Cutting Heat on Machining Accuracy in Ultra-Precision Diamond Turning

CIRP Annals ◽  
1990 ◽  
Vol 39 (1) ◽  
pp. 81-84 ◽  
Author(s):  
Toshimichi Moriwaki ◽  
Akira Horiuchi ◽  
Koichi Okuda
Keyword(s):  
Diamond Turning ◽  
Machining Accuracy ◽  
Cutting Heat ◽  
Ultra Precision

scholarly journals Ultra-Precision Single-Point Diamond Turning of a Complex Sinusoidal Mesh Surface Using Machining Accuracy Active Control

2021 ◽  
Vol 67 (7-8) ◽  
pp. 343-351
Author(s):  
Peixing Ning ◽  
Ji Zhao ◽  
Shijun Ji ◽  
Jingjin Li ◽  
Handa Dai
Keyword(s):  
Active Control ◽  
Tool Path ◽  
Single Point ◽  
Diamond Turning ◽  
Machining Accuracy ◽  
Machining Error ◽  
Machined Surface ◽  
Mesh Surface ◽  
Slow Tool Servo ◽  
Radius Compensation

Single-point diamond turning (SPDT) assisted with slow tool servo (STS) is the most commonly utilized technique in the fabrication of optical modules. However, the tool path significantly affects the quality of the machined surface. In order to realize the determined machining accuracy effectively, a tool path generation (TPG) method based on machining accuracy active control (MAAC) is presented. The relationship between tool path and machining error is studied. Corner radius compensation (CRC) and the calculation of chord error and residual error are detailed. Finally, the effectiveness of the proposed approach is verified through a machining error simulation and a cutting experiment of a complex sinusoidal mesh surface fabrication.

The Improvement of the Machining Accuracy by Factor Analysis Approach

2012 ◽  
Vol 201-202 ◽  
pp. 333-336
Author(s):  
Zheng Hua Huang ◽  
Cheng Rong Jiang
Keyword(s):  
Factor Analysis ◽  
Machining Process ◽  
Analysis Approach ◽  
Machining Accuracy ◽  
Analysis Method ◽  
Machining Error ◽  
Error Sources ◽  
Machining Errors ◽  
Process System ◽  
Statistical Analysis Method

In machining, a complete machining process system consists of the machine tool, the fixture, the tool and the part together, the various errors are also inevitable. The factor analysis approach and the statistical analysis method were put forward to study the machining accuracy on the basis of the error sources analysis of the machining accuracy, and the measures were introduced to improve the machining accuracy by using the factor analysis approach. The change laws are grasped by the analysis of the machining errors, so as to take the appropriate measure to reduce the machining error and improve the machining accuracy.

Analysis of Machining Error in Numerical Control Milling

2013 ◽  
Vol 312 ◽  
pp. 710-713
Author(s):  
Jing Jun Cui
Keyword(s):  
Thermal Deformation ◽  
Numerical Control ◽  
Machining Accuracy ◽  
Machining Error ◽  
Important Indicator ◽  
Multiple Factors ◽  
Machining Errors ◽  
Cutter Wear ◽  
Finished Surface ◽  
Experimental Study Design

Generally speaking, the error in machining is an important indicator measuring the accuracy of finished surface. The machining error often occurs in numerical control milling. Such error will be influenced by multiple factors, such as cutter wear, thermal deformation, machine tool deformation, vibration or positioning error. Nowadays, though our science and technology develops rapidly, machining error problem in numerical control milling occurs frequently. At present, several methods can be applied to forecast machining error problems in numerical control milling, including on the basis of machining theory, experimental study, design study and artificial intelligence. The analysis and forecast of machining error problems in numerical control milling can to some extent improve the degree of machining errors so as to promote the machining accuracy in milling. The author expresses the views on machining error problems according to current situations of numerical control milling.

An Optimal Method of Tool Path Generation for Radial Sinusoidal Surface

2014 ◽  
Vol 1027 ◽  
pp. 20-23 ◽  
Author(s):  
Shi Jun Ji ◽  
Hui Juan Yu ◽  
Ji Zhao ◽  
Jin Chao Li ◽  
Lei Lei Liu
Keyword(s):  
Tool Path ◽  
Tool Path Generation ◽  
Diamond Turning ◽  
Machining Accuracy ◽  
Path Generation ◽  
Optimal Method ◽  
Spiral Tool Path ◽  
Ultra Precision ◽  
Sinusoidal Surface ◽  
Theoretical Analyses

Tool path generation is an important part of ultra-precision manufacturing, and spiral tool path is one typical driving path. For single point diamond turning (SPDT), two methods are commonly used to generate the driving points on the spiral tool path, which are equally spaced angles and equally spaced arcs for two adjacent cutting points. But these two methods both have the defects for machining radial sinusoidal surface with SPDT. In this paper, the theoretical analyses of the two different methods are conducted and compared respectively. Then, an optimal method of generating the spiral cutting tool path is proposed on the base of theoretical analyses, which can avoid disadvantages of two original methods. The proposed method can enhance the machining accuracy and fabricating efficiency for ultra-precision machining of the radial sinusoidal surface with SPDT.

Synthetic Analysis and Simulation of One-Side Processing Profile Error of Globoidal Cam

2013 ◽  
Vol 579-580 ◽  
pp. 105-112
Author(s):  
Xiao Gao Chen ◽  
Zi Hua Hu
Keyword(s):  
Theoretical Calculation ◽  
Error Modeling ◽  
Machining Accuracy ◽  
Calculation Error ◽  
Motion Error ◽  
Synthetic Model ◽  
Machining Errors ◽  
Normal Error ◽  
The One ◽  
Multi Body

Aiming at globoidal cam one-side machining errors in addition to programming error, there exists combined effects of a number of the original errors, such as, machine motion error, tool error, fixture error and et al. On basis of the analysis of the principle of one-side processing, the theoretical calculation synthetic model of the one-side machining profile normal error is established based on the multi-body system error modeling theory and spatial mechanism conjugate meshing principle. And by applying Newtons iterative method and simulations in Matlab, the law of comprehensive influence of each original error on globoidal cam profile normal error is revealed. The simulation results verify the correctness of the theoretical calculation error synthetic model, and a scientific proof is provided for further improving machining accuracy of one-side machining of globoidal cam.

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