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2017 | Buch

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Ultraprecision Machining of Hybrid Freeform Surfaces Using Multiple-Axis Diamond Turning

verfasst von: Dennis Wee Keong Neo

Verlag: Springer Singapore

Buchreihe : Springer Theses

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

This thesis focuses on producing hybrid freeform surfaces using an advanced diamond-turning process, understanding the generation of surface accuracies (form errors) and how the choice of cutting strategies affects these, as well as simplifying the complications of generating cutting paths for such freeform surfaces. The breakthroughs behind this thesis are the development of novel, multiple-axis, diamond turning techniques to overcome the limitations of conventional diamond turning processes, an analytical model to optimize the generation of ultraprecise freeform surfaces, and an add-on tool path processor for CAD/CAM software solutions. It appeals to researchers and scholars with a strong machining background who are interested in the field of manufacturing ultraprecise freeform surfaces or in the field of optimizing ultraprecision machining processes.

Inhaltsverzeichnis

Frontmatter

Chapter 1. Introduction

Abstract

Freeform optical surfaces are widely used to reduce wavefront error and sizes as compared to rotational surfaces. Ultraprecision machining techniques such as diamond turning with fast tool/slow slide servo (FTS/SSS) and diamond micromilling techniques are widely employed for machining freeform optical surfaces with ultraprecision accuracy and excellent surface quality.

Dennis Wee Keong Neo

Chapter 2. Literature Review

Abstract

In this chapter, a literature survey on the manufacturing processes of hybrid freeform surfaces is presented. Section 2.1 discusses the main principles and the limitations of FTS/SSS diamond turning and other multiple-axis diamond machining techniques. Section 2.2 covers the existing CAD/CAM/CAE technologies employed for the manufacturing of hybrid freeform surfaces, and discusses the needs for the surface generation methodologies to produce an accurate hybrid freeform surface. Lastly, Sect. 2.3 presents the concluding remarks that lead to this dissertation.

Dennis Wee Keong Neo

Chapter 3. Initial Development of CAD/CAM Technologies

Abstract

This chapter presents an initial development of CAD/CAM technologies which implement Visual Basic application programming interface (API) into the SolidWorks platform to generate accurate toolpaths for diamond turning of hybrid freeform surfaces.

Dennis Wee Keong Neo

Chapter 4. Development of Hybrid FTS/SSS Diamond Turning

Abstract

This chapter presents a hybrid fast tool and slow slide servo (FTS/SSS) diamond turning process with layered tool trajectories to address the limited FTS travel length and low bandwidth in the existing machine tool.

Dennis Wee Keong Neo

Chapter 5. Novel Surface Generation of Complex Hybrid Freeform Surfaces

Abstract

This chapter presents a novel surface generation technique with multiple machining axes to address the loss of symmetrical axes in the machining of complex hybrid freeform surfaces. An automated Guilloche machining technique (AGMT) has been developed in the multiple-axis diamond turning machine to address the loss of symmetry. Fresnel lens array is one of these complex hybrid freeform surfaces, which consists of several elements of Fresnel lenses arranged in a rectangular or hexagonal layout. In general such array of Fresnel lenses is manufactured individually and assembled, which cannot be achieved in a single process.

Dennis Wee Keong Neo

Chapter 6. Development of Surface Analytical Model for Accurate Hybrid Freeform Surfaces

Abstract

This chapter presents a novel surface analytical model to determine the cutting linearization error for several cutting strategies. From the previous studies in Chap. 4, when one of the cutting strategies, constant-angle, has been employed, the surface quality of machined freeform surfaces is strongly dependent to the number of points per revolution N _p. This is due the induced cutting linearization errors in the spiral cutting direction, as explain earlier in Chap. 2. From literatures, it is also reported that a uniform machined surface quality could be obtained by employing another cutting strategy, constant-arc cutting strategy (Yu et al. in Meas Sci Technol 22(1):015105, 2011 [1]).

Dennis Wee Keong Neo

Chapter 7. Integration and Implementation

Abstract

This chapter presents an overall integration of the proposed methodologies throughout this dissertation. The primary objective of the integrated system is to construct the software tools for planning and conducting the manufacture of hybrid freeform surfaces using the multiple-axis ultraprecision machining process.

Dennis Wee Keong Neo

Chapter 8. Conclusions and Recommended Future Works

Abstract

In this study, an attempt of integrating the multiple-axis diamond turning processes with the proposed methodologies into the CAD/CAM system was made. Hence, there are four major contributions for optimizing the ultraprecision

Dennis Wee Keong Neo

Backmatter

Titel: Ultraprecision Machining of Hybrid Freeform Surfaces Using Multiple-Axis Diamond Turning
verfasst von: Dennis Wee Keong Neo
Verlag: Springer Singapore
Electronic ISBN: 978-981-10-4083-2
Print ISBN: 978-981-10-4082-5
DOI: https://doi.org/10.1007/978-981-10-4083-2

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