Ultrasonic elliptical vibration cutting (UEVC) is attracting much attention in ultra-precision machining of brittle materials as it was found be able to increase the critical depth of cut (dc) of brittle materials. However, there are few studies on the prediction of dc for UEVC of brittle materials. In this study, a predictive model was developed for the prediction of dc in microgroove plunge-cutting with respect to several factors, including the distance from transient surface to target surface (DTSTS), the actual undeformed chip thickness (UCT), the critical UCT (tc) and crack length (Cm). Experiments on plunge-cutting of KDP crystal were conducted. Results showed the predicted dc matches well with the experimental ones.
Ultra-precision noncircular optical components, e.g. hyperbolic quadrupole in mass spectrometer, can be machined by diamond turning assisted by slow tool servo (STS). However, the bandwidth of STS is usually small, which limits the STS's capability in following the required tool path, leading to a large form error. To reduce the form error, this paper proposes an approach to apply variable spindle speed (VSS) to STS-based turning. Design of the VSS trajectory based on the noncircular profile of the optical component was investigated in detail. To validate the proposed approach, simulation on the application of VSS in the STS-based turning process was established and applied to the machining of typical noncircular optical components. Simulation results show that the proposed approach is effective in reducing the requirement on the bandwidth of the STS, resulting in higher form accuracy of the machined noncircular optical components.
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