Simulation And Experimental Study On Ultra-Precision Turning Of Micro-arc Diamond Tool

Single point diamond ultra-precision turning(SPDT)has become one of the most important machining techniques for the preparation of high surface quality components.Micro-arc diamond cutting tools can be used to improve the manufacturing accuracy through grinding and other means,but there is always a certain deviation in any case,so when using micro-arc diamond cutting tools to process the workpiece,the error compensation method can be used to improve the machining accuracy.In order to obtain the influence law of tool corrugations on the surface quality and surface shape accuracy of the workpiece,this paper established a numerical simulation model by using Matlab software,and carried out a numerical simulation study of different feed speeds and tool tip radius under different tool corrugations.Firstly,the tool is measured with radius amplitude meter.According to the measurement results,two kinds of typical tool waviness are obtained,namely,medium frequency small value waviness and low frequency large value waviness.Then,the theoretical derivation of the turning process was carried out.According to the theoretical derivation,a numerical simulation model was established by using Matlab software,and the influence of the medium frequency small value ripple degree and low frequency large value ripple degree on the surface quality and surface shape accuracy of the workpiece was studied under different feed speeds and the radius of the tool tip.The experiment of micro-arc ultra-precision turning is carried out,and the surface quality and surface shape accuracy of the processed arc surface are detected by using the white light interferometer and profiler.The influence law of tool ripple on the surface quality and surface shape accuracy of the workpiece is obtained by combining with the simulation results.It is found that machining texture on tool front surface can improve cutting performance and workpiece surface quality.Therefore,this paper also carried out the machining of micro texture on the diamond tool's front cutting surface,and established the two-dimensional orthogonal cutting finite element simulation model with ABAQUS software.Combined with the ultra-precision cutting experiment,the influence of micro texture tool on the machining process and the surface quality of the workpiece was studied.The finite element simulation model was established and the finite element simulation research of diamond microtexture cutting tool was carried out systematically.The influence of texture shape on chip and workpiece surface quality during machining was studied.Then the effects of texture width,texture depth,texture spacing and the distance from texture starting position to cutter edge on chip and workpiece surface quality were studied,and the texture parameter combination with the best comprehensive performance was obtained.