Design Of The Large Stroke Two-Axis Fast Tool Servo For Ultra Turning

With the development of science and technology, the free surface opticalcomponents have a great application requirement in aviation, spaceflight, national defense,digital cameras and automotive fields and so on, because of its good optical performanceand light quality. However, the key factor of its application and development is how toconstruct free surface optical components with high efficiency and high precision. For thisphenomenon, basing on large number of researches and practices, the researchers at homeand abroad generally believed that the diamond turning based on fast tool servo (FTS) isone of the most promising methods for the construction of free surface optical components.Through consulting a large number of documents found that, mostly existing FTS craftdevices have only one degree of freedom, either one degree of freedom of linear or onedegree of freedom of swinging, these one degree of freedom FTS craft devices are unableto realize non-equal-parameters for the tool path planning, some of the only two degreesof freedom FTS craft devices’ stroke can only reach micron level, all of these are greatlylimit the application and development of FTS technology.In reaction to the phenomenon, basing on consulting a large number of literaturematerials, this paper developed a new type of large stroke two axis linear FTS craft device,which can realize millimeter stroke in the direction of each degree of freedom, this workprovides an important reference for the development and application of the FTS technology.The main research content of this paper includes the following several aspects:(1) Basing on the research of the construction method for the free surface opticalcomponents with their advantages and disadvantages at home and abroad, this paperstudied the development of FTS at present situation and analyzed the advantages anddisadvantages of all kinds of FTS craft devices according to the different driver.(2) Through the layout design of movement axis, the state of mechanism compositionand working principle, this paper completed the overall design for the FTS device; basingon the selection of driver and detecting element, through the detailed structure design ofkey parts, this paper completed the design of a large stroke two degrees of freedom FTScraft device prototype development work. (3) Through the statics and dynamics analysis for FTS device, this paper studied itsstatic characteristics and dynamic characteristics. The analysis results suggested that theFTS device could meet all of the requirements in stroke, frequency response and intensitywhich were designed in this paper.(4) Basing on the mechanical analysis of FTS device, this paper extracted six mainstructure design parameters which had the greatest influence on its performance, andbasing on this, this paper carried the correlation analysis experiments for the designparameters of FTS device. After that, this paper calculated the correlation matrix betweenstructure parameters and performance parameters, realized the sensitivity analysis and thecorrelation analysis for the main structure design parameters of the FTS device, and finallyobtained the response surfaces for all of the performance parameters.(5) Basing on the correlation analysis, with the goal of the maximizing the first-ordernatural frequency constrained with the strokes in the direction of each degree of freedomand the maximum equivalent stress, this paper optimized the main structure designparameters of FTS device using the nonlinear Lagrange quadratic programming (NLPQL)method, thereby greatly improved the mechanical characteristics and the reliability of theFTS device.(6) Basing on elaborating the step of system identification, this paper selected theinput signal and the sampling frequency, and carried the experiment of systemidentification for FTS device. Finally, the transfer function model was successfully used toidentify the model of FTS.