Study On Vibration Characteristics During Ultra-precision Fly-cut

With the rapid development of the industry, the requirements of machiningaccuracy are also increasing. So the research of ultra-precision machining has becomemore and more important content in mechanical processing. Fly cutter milling with highcutting line speed, high efficiency, and high quality of machined surface is an importantmethod for ultra-precision machining. But the fly cutter milling’s process isintermittently and it is single point cutting. The cutting force with pulse characteristicsis easy lead to processing vibration. It can affect the surface quality of the workpiece, soit is necessary to research the vibration of machine in processing.This paper describes the main structure and the important parameters of the studiedfly cutting machine tools. This paper analyzes a variety of factors that cause machinevibration. To make preparations for vibration analysis this paper builds cutting forcemodel and calculates the cutting force.This paper deduces film pressure distribution functions through theoreticalcalculation, on the basis of this function calculates the spindle bearing capacity andstiffness of the film. Establishes physical and mathematical models of spindle vibration,shaft vibration differential equations are solved by numerical methods, combined withthe experiment analysis of different processing parameters on the spindle vibration. Theradial vibration amplitude of aerostatic spindle is about1nm under the conditions ofultra-precision machining.This paper analyzes the static characteristics of aerostatic spindle through FLUENT,compares the results with theoretical calculations to verify the gas film pressuredistribution, the theoretical capacity and stiffness analysis is correct, analyzes theinfluence of different parameters on the static characteristics of the spindle investigated,Establishes a spindle and guideway vibration model by ANSYS, obtained the influenceof different parameters on spindle vibration.This paper experiments on the vibration of the spindle and the guideway. Theexperimental data were processed and analyzed in detail, obtains the vibration ofspindle and guideway in different processing conditions, compares the experiment datawith the theoretical analysis and simulation results to verify the correctness of thetheoretical analysis and simulation analysis, the minimum value of the surfaceroughness of the diamond cutting is0.014μm by detecting machined surface and obtainsthe influence of different parameters on surface roughness.