Fly Cutting Technology for Ultra-precision Machining (Precision Manufacturing)

✍ Scribed by Suet To (editor), Sujuan Wang (editor)

• Publisher: Springer
• Year: 2023
• Tongue: English
• Leaves: 466
• Edition: 1st ed. 2023
• Category: Library

✦ Synopsis

This handbook covers the fly cutting technique, an ultra-precision mechanical machining technology which is regarded as the fastest and most reliable low-cost machining method to generate high quality complex surfaces. The ultra-precision raster milling provides more flexibility and suitability for freeform and structural surfaces with a uniform quality with sub-micrometric form error and nanometric surface roughness. These surfaces are widely applied into optics, medicine, biotechnology, electronics, and communications. The fundamental and latest advancing knowledge of fly-cutting technology is important for the future development and applications in ultra-precision mechanical machining technology. This book provides a good reference for fly-cutting technology in ultra-precision machining for undergraduate and postgraduate students, researchers, engineers, and postdoctoral fellow in advanced manufacturing area. It gives the audience an overview of the working principles, process mechanism, salient features, applications, and research directions of ultra-precision fly-cutting technology.

✦ Table of Contents

Series Preface
Volume Preface
Contents
About the Series Editor
About the Volume Editors
Contributors
1 Modeling of Surface Generation with Cutting Strategy Effect in Ultraprecision Raster Milling
Introduction
Development of Cutting Strategy
Tool Path Generation
Transformation Between Machine and Workpiece Coordinate System
Machining Time Evaluation
Evaluation of Tool Path Length
Real Feed Rates of Machine Axes
Cutting Time Estimation
Surface Generation Model
Material Removal Mechanism
Surface Roughness Topography Pattern
Effect of Tool-Interference on Surface Generation
Feed-Interval and Path-Interval Scallop Height Without Shift Length
Effect of Shift Length on Scallop Heights Without Tool-Interference
Effect of Shift Length on Scallop Heights with Tool-Interference
3D Kinematic Model of Surface Roughness Prediction
Experimental Verification
Experiment Design
Experimental Results
Results and Discussion
References
2 Modelling of Spindle Vibration and Cutting Mechanism in Ultra-precision Raster Milling
Introduction
Surface Formation in Ultra-Precision Raster Milling
Cutting Strategies
Cutting Directions
Fundaments of Modelling of Spindle Motions
Eulerian Angles
Newton-Euler Equations
Dynamic Modelling of an Aerostatic Bearing Spindle in UPRM
Dynamic System of a Spindle
Cutting Force Description
Dynamic Equations of Spindle Motions
Summary
References
3 Dynamic Characteristics of Spindle Vibration in Ultraprecision Raster Milling
Introduction
Dynamic Characteristics of Spindle Vibration in UPRM
Solutions of Spindle Motion Equations
Dynamic Responses of the Spindle Under Intermittent Cutting Forces
Influences of Intermittent Cutting Forces with Spindle Speed
Influences of Depths of Cut with Spindle Speed
Summary
References
4 Prediction and Optimization of Surface Generation Under Spindle Vibration in Ultra-precision Raster Milling
Introduction
Surface Generation in UPRM
Modeling of Surface Generation
Surface Topography
Shift Length of Tool Loci and Phase Shift of Vibration Influencing Surface Topography
Prediction of Vibration Effects on Surface Topography
Optimization of Vibration Effects on Surface Topography
Summary
References
5 Modelling and Optimization of Cutting Strategy on Freeform Machining in Ultra-precision Raster Milling
Introduction
Modeling of Surface Generation on Freeform Machining
Error Analyses on Freeform Machining
Effect of Cutting Strategy on Form Accuracy of Freeform Surface
Framework of Cutting Strategy Optimization
Effect of Cutting Strategy on Machining Time
Effect of Cutting Strategy on Surface Finishing
Effect of Cutting Feed Rate, Spindle Speed, and Path-Interval on Surface Roughness
Effect of Feed Direction on Surface Roughness
Effect of Shift Ratio and Depth of Cut on Surface Roughness
Optimization Methodologies of Cutting Strategy
The Integrated Optimization of Cutting Feed Rate and Path-Interval
Tool Path Optimization
Experimental Study of Effect of Cutting Strategy on Surface Roughness
Effect of Path-Interval on Surface Roughness
Effect of Depth of Cut on Surface Roughness
Effect of Entry Distance on Surface Roughness
Effect of Feed Direction on Surface Roughness
Verification of Cutting Strategy Optimization Methodologies
Quality-Optimal Cutting Strategy Optimization Methodology
Time-Optimal Cutting Strategy Optimization Methodology
Effect of Cutting Strategy on Form Error
Summary
References
6 Modelling and Characterization of Material Effect on Surface Generation in Ultra-precision Raster Milling
Introduction
Material Elastic Recovery Effect on Cutting Profiles
Modelling of Material Elastic Recovery on Surface Roughness
Calculation Model of the Local Axial Depth of Cut
Material Elastic Recovery Effects on Scallop Heights
Surface Roughness Prediction Model with Material Elastic Effects
Characterization of Material Effects on Surface Roughness
Experimental Study on Material Effects on Surface Generation
Experiment Design
Surface Roughness Prediction Under Material Elastic Recovery
Characterization of Material Effect on Surface Generation
Effects of Hard Particles on Surface Finishing in Machining Al6061
Summary
References
7 Tool Wear Characteristics in Ultra-precision Raster Milling
Introduction
Diamond Tool Wear Characteristics
Experimental
Experimental Setup
Experimental Procedures
Cutting Distance Calculation
Tool Wear Characteristics and Their Effects
Fracture Wear
Material Welding
Flank Wear Land Formation
Sub-Wear-Land Formation
Summary
References
8 Tool Wear Monitoring Method Using Cutting Force in Ultra-precision Raster Milling
Introduction
Experiments
Experimental Setup
Cutting Force Acquisition
Cutting Force Components
Modeling and Analysis of Cutting Force in UPRM
Modeling of Cutting Force Pulse
Investigation of Cutting Force Composition
Cutting-Force-Induced Free Vibration
Effects of Cutting Parameters on the Amplitude of Cutting Force
Cutting Force Evolution with Tool Wear Progress
Experimental Observations
Theoretical Interpretation
Power Spectrum Density Characteristics of Cutting Force Under Tool Wear
PSD Characteristics of Cutting Force
PSD of the Free Vibration of Dynamometer
PSD of the Modal Vibration of Workpiece
Summary
References
9 Tool Fracture Wear Evaluation Method Using Cutting Chips
Introduction
Mechanical Tool Wear Mechanisms
Thermal-Chemical Tool Wear Mechanisms
Tool Wear Suppressing Methods
Chip Formation in the Cutting Process
Relationship Between Tool Wear and Chip Formation
Experiment
Results and Discussion
Modeling of Cutting Chip and Virtual Cutting Edge
Cutting Chip Model
Virtual Cutting Edge Buildup Under Tool Fracture Wear
Modeling and Analysis of Surface Roughness Under Tool Fracture Wear
Surface Topography Simulation Under Tool Fracture Wear
Surface Roughness Evaluation Under Tool Fracture Wear
Summary
References
10 Tool Flank Wear Evaluation Method Using Cutting Chips
Introduction
Tool Wear Monitoring Methods
Direct Tool Wear Detection Methods
Indirect Tool Wear Monitoring Methods
Experiments
Results and Discussion
Modeling and Identification of Flank Wear Land
Chip Thickness Along the Feed Direction
Wear Land Angle Identification
Wear Land Width Calculation
Modeling and Analysis of Surface Roughness Under Tool Flank Wear
Surface Roughness Modeling Under Tool Flank Wear
Effects of Cutting Parameters on the Surface Roughness Under Tool Flank Wear
Summary
References
11 Ductile Machining of Brittle Materials by Ultra-precision Raster Milling
Introduction
Experiments and Methodology
Brittle-to-Ductile Transition in UPRM of Brittle Material
Characteristics of the Surface Topography
Cutting Forces in UPRM of Brittle Material
Summary
References
12 Ductile Machining Mechanism for Micro-structure by Ultra-precision Raster Milling
Introduction
Cutting Mechanism in UPFC of Micro-groove
Ductile Machining Model in UPFC of Micro-groove
Effect of Machining Parameters
Ductile Machining of Micro-structures by UPFC
Micro-grooves Fabricated by UPFC
Surface Micro-topography
Material Phase Transformation
Chip Morphology
Tool Wear
Summary
References
13 Ductile Machining Mechanism for Continuous Freeform Surface by Ultra-precision Raster Milling
Introduction
Cutting Mechanism for UPFC of Freeform Surface
Ductile Machining Model in UPFC of Freeform Surface
Modeling of Asymmetrical Chip Formation
Effect of Machining Parameters
UPFC of Freeform Surface on Brittle Materials
F-theta Lens
Machining Efficiency UPFC
Tool Wear in UPFC of Freeform Surface
Summary
References
14 One-Step Generation of Hybrid Structured Surface on Brittle Material by Ultra-precision Raster Milling
Introduction
Machining Principle of Hybrid Micro-optics
Optimal Toolpath Generation Strategy
Determination of SCPs
Selecting Criteria of Machining Parameters
Analysis of the Fabricated Hybrid Micro-optics
Hybrid Micro-lens Arrays
Hybrid Sinusoid Freeform Surface with Nano-gratings
Summary
References
15 Optimization Modeling of Biomimetic Structures for Self-Cleaning and Optical Performance in Ultra-precision Raster Milling
Introduction
Design Criteria of Surface Geometry
Self-Cleaning Performance Requirements
Optical Performance Requirements
Consideration of Machining Ability
Design Challenge
Structure Design
Mathematical Model of Micro-Directional Grooved Surfaces
Mathematical Model of Micro-pillar Surfaces
Experimental Procedures
Fabrication of Micro-Patterns Using Ultra-Precision Raster Milling
Surface Topography Measurement
Contact Angle Measurement
Results and Discussion
Static Contact Angle Measurement
Length of Water Droplet Elongation
Optical Testing of Biomimetic Structures
Summary
References
16 Wetting Characteristics of Micro-patterned Surfaces Fabricated by Ultra-precision Raster Milling
Introduction
Experimentation
Experimental Setup
Fabrication of Micro-patterned Surfaces
Micro-patterned Surface Topography
Results and Discussion
Comparison with the Theoretical Models
The Wenzel Model
The Cassie and Baxter Model
Static Contact Angle from the Experiment
Droplet Anisotropy
Droplet Contact Line
Contact Angle Hysteresis
Sliding Angle Measurement
Summary
References
17 Characterization of Intermediate Wetting States and Anisotropic Sliding on Micro-directional Grooved Surfaces
Introduction
Theoretical Analysis
Static Contact Angle
Contact Angle Hysteresis
Experimental Section
Results and Discussion
Surface Characterization
Observation of Droplet Contact Line
Validation of Theoretical Models
Sliding Angle Measurement
Contact Angle Hysteresis
Summary
References
18 Anisotropic Wetting of Micro-Micro Hierarchical Structures Fabricated by Ultra-precision Raster Milling
Introduction
Regular Micro-hierarchical Structures Fabricated by UPRM
Experimental Setup
Fabrication of Regular Micro-hierarchical Structures
Surface Topography Measurement
Results and Discussion
Irregular Micro-Micro Hierarchical Structures Fabricated by EFCS
Experimental Setup
Fabrication of Irregular Micro-Micro Hierarchical Structures
Surface Topography Measurement
Results and Discussion
Multi-level Hierarchical Structures Fabricated by EFC
Experimental Setup
Fabrication of Multi-level Hierarchical Structures
Surface Topography Measurement
Results and Discussion
Summary
References