Quality Inspection And Evaluation Of Diamond Tool Arc Profile Based On Cutting Area Analysis

Ultra-precision cutting technology is a key technology for the national living standards improving and the national defense building.In addition to ultra-precision machine tool and a stable processing environment,an ultra-precision diamond tool is also an indispensable important condition for ultra-precision cutting.With the development of ultra-precision cutting technology,the influence of tool on processing quality is becoming more and more important.It is one of the important factors affecting the level of ultra-precision cutting processing technology.Evaluating the quality of the arc profile of the tip of diamond tools can not only provide the basis for the selection and use of the tool,monitor the wear status of the tool,but also guide the tool sharpening process,improve the tool manufacturing level,and improve the surface quality of ultra-precision machining.The development of ultra-precision cutting technology is of great significance,and can provide strong support for the defense industry,civil high-end component manufacturing,cutting-edge scientific research and other fields.With the development of testing equipment and testing methods,the measurement accuracy of the tool tio is gradually improved,and the measurement accuracy of the nanometer level can be realized.Among the various equipment that can be used to measure the tool tip,the atomic force microscope(AFM)has the highest measurement accuracy and can meet the needs of the quality evaluation of the arc profile of the ultra-precision diamond tool tip.AFM can only measure the small area of the circular arc profile.Although its range can be extended by the rotary axis system,limited by the hardware conditions,its sampling interval is large,and the lateral measurement resolution is poor.Arc Waviness is an important indicator for evaluating the quality of the tool tip arc,and its value is generally one hundred nanometers or less.Filtering is an important part of waviness evaluation,but the waviness of ultra-precision diamond tools on the order of 100 nanometers has exceeded the evaluation range of existing international and national standards,and the selection of filter types has not been studied in depth.In view of the problem that the lateral range and solution cannot been taken into account in the measurement of tool tip arc profile;the selection of the filter type in the evaluation of waviness,atc.,the following research is carried out:First of all,the arc of the tool tip involved in the ultra-precision cutting is analyzed,for the two different situations of curved turning and plane flying cutting,the circular arc contours of the tool tip to be measured are in the order of millimeters and micrometers,respectively,ensuring that the measurement results and the actual participation in the cutting process is corresponding.For the millimeter-level arc contour of the tool tip,the tool tip arc measurement method based on the atomic force microscope and the precision rotary shaft system is applied.For the micrometer-level arc contour of the tool tip,the atomic force microscope is used for direct measurement,and the policy of segmented multiple measurement is used.The strategy discusses in detail the principle,process and steps of ultra-precision measurement of the circular arc profile of the tool tip.Then,the study on the evaluation of the quality of the arc profile of the ultra-precision diamond tool tip is done.Based on the measurement data of the millimeter-level arc contour of the tool tip,the measurement error introduced by the bias of the axis of the precision rotary shaft system and the arc center of the tool tip during the measurement process is analyzed.The separation of the bias error in the actual measurement data is realized under the Matlab software,which improves the repeatability of the measurement results of the arc profile in the order of millimeters of the tool tip.For the waviness evaluation of the millimeter-level arc contour of the tool tip,based on the simulated contour and the actual measurement data,the common contour filters are compared,and it is determined that the spline filter is more suitable for the waviness evaluation of the millimeter-level arc contour of the tool tip than the Gaussian filter.Aiming at the micron-level arc profile of the tool tip,the data stitching algorithm of the micron-level arc profile is implemented based on the iterative closet point.The measurement and data stitching experiments are carried out to realize the comprehensive characterization of the three-dimensional shape of the micrometer-level arc profile of the tool tip.Finally,an experimental study on cutting machining to verify the validity of the measurement results of the arc profile of the tool tip is carried out.Aiming at the millimeter-level arc contour of the tool tip,the cutting machining simulation of the hemispherical workpiece is designed,and the experimental study of ultra-precision turning of the hemispherical workpiece is carried out.The influence of the millimeter-level arc contour of the tool tip is analyzed,the validity of the micrometer-level arc contour measurement result of the tool tip is verified.The ultra-precision flying cutting experiment of KDP crystal is carried out for the micrometer-level arc contour of the tool tip,which verifies the validity of the micrometer-level arc contour measurement result of the tool tip.