Optimization of fast tool servo diamond turning for enhancing geometrical accuracy and surface quality of freeform optics

Lin Zhang, Yusuke Sato, Jiwang Yan

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Fast tool servo (FTS) diamond turning is a promising technique for high-precision generation of freeform optics with remarkable efficiency. However, the conventional constant scheme for control point sampling fails to consider the surface variation, which might lose some details of the surface profile and result in low form accuracy and non-uniform surface quality. Facing this issue, this manuscript proposes a novel optimization method for control points sampling, which restrains the deviations and contains as much of the surface details. In the optimization method, the sampling intervals between two adjacent control points are actively adjusted to adapt the surface variation of the desired surface. By adopting this method, the sampling induced interpolation error between the control points is restrained within the tolerance and eliminates lack/over-definition of control points in the machining area. The feasibility of the proposed optimization method is demonstrated by both theoretical prediction and fabrication experiment of sinusoid freeform surface. Compared with the conventional sampling method, both the predicted and measured form error of the proposed method are remarkably reduced about 35 % with the same amount of control points. This technique provides a new route to sampling control points in FTS diamond turning to achieve high accuracy and flexible fabrication of freeform surface machining.

Original languageEnglish
Title of host publicationEuropean Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022
EditorsRichard K. Leach, A. Akrofi-Ayesu, C. Nisbet, Dishi Phillips
Publishereuspen
Pages491-494
Number of pages4
ISBN (Electronic)9781998999118
Publication statusPublished - 2022
Event22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022 - Geneva, Switzerland
Duration: 2022 May 302022 Jun 3

Publication series

NameEuropean Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022

Conference

Conference22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022
Country/TerritorySwitzerland
CityGeneva
Period22/5/3022/6/3

Keywords

  • control points
  • desired tolerance
  • Fast tool servo
  • optimization sampling method

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering
  • Mechanical Engineering
  • Environmental Engineering
  • General Materials Science
  • Instrumentation

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