| In ultra-precision diamond turning, the quality of a machined surface that can be generated is important in assessing the performance of the machining system. Although some attempts have been made in the development of machining models to simulate surface topography of a workpiece, most of them focused on the synthesis of surface topography from the data derived from interferometry or Scanning Electron Microscopy (SEM). Few deterministic models have been found to simulate the generation of surface topography based on machine kinematics, material science and cutting theories. The influences of crystallographic orientation and other properties of the work materials, and their interaction with the surface generation have been overlooked in most of the current models.; An investigation has been conducted into the factors affecting the surface generation in ultra-precision diamond turning.; In order to measure quantitatively the effect of material swelling and anisotropy on the surface generation, a Multi-spectrum Analysis Method has been adopted in the study. In this method, various features of a diamond turned surface are extracted and analyzed by the spectrum analysis of its surface roughness profiles measured at a finite number of radial sections of the diamond turned surface.; However, the multi-spectrum analysis method is incapable of determining the exact contribution of each factor upon the overall surface roughness. To overcome this shortcoming, a Multiple Data Dependent Systems (MDDS) analysis method is proposed.; A 3-D surface topography simulation model for ultra-precision diamond turning is proposed. The model takes into account the effect of tool geometry, machining conditions and tool-workpiece vibration.; Ultra-precision diamond turning is an expensive process. Nowadays, the achievement of a super mirror finish in many current industrial applications still depends much on the experience and skills of the machine operator through an expensive trial and error approach when new materials or new machine tools are used. The successful development of the surface topography model and the model-based simulation system can help to identify the optimal cutting conditions for different work materials without the need for costly trial and error cutting tests. (Abstract shortened by UMI.)... |
