| Mechanical parts with particular microstructure surface are widely used incommunication technology, measurement equipment, image system, biotechnology,military and many other fields because of their physical and chemical properties. Inrecent decades, microstructure surface technology has realized a rapid development dueto a number of studies done by countries all around the world. As the development ofultra-precision lathe and improvement of machining accuracy, it’s possible to processmicrostructure surface in mechanical way. Single Point Diamond Turning(SPDT) withFast Tool Servo(FTS) may be a choice to make mass production possible, because of itspredicted machining precision, flexibility and low cost. So it’s necessary to research onFTS turning processing simulation and control.FTS cutting tool selection, path generation as well as microstructure processingsimulation and experiment for the FTS turning processing have been done in thisdissertation.The problem of diamond cutting tool selection for machining microstructuresurfaces with different parameters has been solved. Additionally, a set of practicalsoftware to calculate the tool geometry parameters is developed using MATLAB GUI.Nearly arc-length tool path generation algorithm which generates tool tip trajectorypoints in nearly arc-length is proposed. Newton iterative method is used to calculate theneighboring contour tangent point coordinate value, thus the tool nose radiuscompensation was completed.To ensure the correctness of processing program and improve the efficiency andquality, this dissertation has built a controlling model of ultra-precision lathe inMATLAB/Simulink environment. With generated tool tip trajectory points as input, themodel output data points can be used to predict the surface shape, error and quality.A precision worktable with high resolution has been designed for FTS raising andfalling conveniently according to overall placement structure of ultra-precision lathe.And the effect on profile of microstructures caused by tool setting error was discussed.Based on the researches above, two kinds of sinusoidal grid surfaces have beenmachined successfully on the lathe. One of them is of two70μm sine-waves with4μmPV value and the other two200μm sine-waves with4μm PV value, and the surface wasperfect in the test. In this way, the tool path generation algorithm was verified. |
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