Title: Diamond turning of microstructured surfaces: modelling and simulation

Authors: Yuanhua Yang, Shijin Chen, Kai Cheng, Xizhi Sun

Addresses: Precision Engineering Research Institute, Harbin Institute of Technology, Harbin 150001, PR China. ' Precision Engineering Research Institute, Harbin Institute of Technology, Harbin 150001, PR China. ' School of Engineering and Design, Brunel University, Uxbridge UB8 3PH, UK. ' School of Engineering and Design, Brunel University, Uxbridge UB8 3PH, UK

Abstract: In this paper a novel approach is presented for predicting the surface features and surface quality before they are machined. An integrated dynamic model is constructed from the control system point of view and used to simulate the diamond turning process based on the machining principle and taking a number of factors into account. With the simulation model, the form error and roughness of the microstructured 3D surface are calculated and the effects of feed rate and the tool nose radius on the surface topography are systematically investigated. The proposed approach leads to better understanding of the microcutting mechanics of microstructured surfaces and effective and helpful in digitally constructing 3D precision surfaces at design stage. Furthermore, it is promising and has great potential for industrial applications with particular reference to optimisation of the cutting processes and control of the surface functionality in precision machining.

Keywords: microstructured surfaces; diamond turning; 3D surface topography; simulation; nanomanufacturing; dynamic modelling; surface features; surface quality; form errors; surface roughness; microstructure; feed rate; tool nose radius; microcutting mechanics; precision machining.

DOI: 10.1504/IJNM.2007.014613

International Journal of Nanomanufacturing, 2007 Vol.1 No.5, pp.627 - 640

Published online: 21 Jul 2007 *

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