Research On Virtual Machining Platform And Dynamic Simulation Of Ultra-precision Turning

Ultra-precision machining is a very important ultra-precision machining method,which is applied in highly efficient,precise and automated machining of free-form surfaces.It demonstrates the industrialization level of a country.Ultra-precision machining becomes more difficult recently with the increasing application requirements of freeform optics.The machining method,machining parameters and machining procedures should be taken into consideration based on machined devices' characteristics before fabrication.Moreover,whether there will be interference,overcutting phenomenon between machined parts and lathes,and other issues should be analyzed.Especially for the array-type devices requiring highly complex form shape,these factors are more remarkable in simulations and machining process.It is therefore necessary for the simulation system with analysis and calculation functions.This kind of platform would not only help to optimize the machining procedures and then shorten the development cycle,but also improve machining efficiency and product quality.This paper focused on the key technical issues of virtual ultra-precision machining through the fabrication of microlens array.The main work of the paper is as follows,1.An ultra-precision five-axis simulation platform was established based on the Open CASCADE software library.It can generate the machine model,tool model and freeform surfaces,which are modeled by partitioning NURBS fitting method.2.A motion simulation method of ultra-precision five-axis machining was proposed,which achieves the dynamic machining simulation of material removal through the cutting tool scanning body theory.The discrete method was used for the rapid characterization of machined surfaces to acquire machined devices rapidly.3.A sine-transition cutting path generation method was proposed to avoid the surface texture problems existed in the microlens array machining.The contrast experiment results proved its validity and the ability of improving the surface uniformity simultaneously.