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Title: | A novel long-stroke fast tool servo system with counterbalance and its application to the ultra-precision machining of microstructured surfaces |
Authors: | Huo, D Niu, Z Chen, W Cheng, K |
Keywords: | fast tool servo;hybrid control algorithm;counterbalance;system vibration;microstructured surface |
Issue Date: | 26-Mar-2022 |
Publisher: | Elsevier Ltd. |
Citation: | Gong, Z., Huo, D., Niu, Z., Chen, W. and .CHeng, K. (2022) 'A novel long-stroke fast tool servo system with counterbalance and its application to the ultra-precision machining of microstructured surfaces', Mechanical Systems and Signal Processing, 173, 109063, pp. 1 - 20. doi: 10.1016/j.ymssp.2022.109063. |
Abstract: | Copyright © 2022 The Authors. This paper presents a novel long-stroke fast tool servo (FTS) system with counterbalance and its application to the diamond machining of microstructured surfaces. The FTS system is driven by a voice coil motor and guided by air bearings. A hybrid control algorithm which combines PID control, sliding mode control and feed-forward control was specifically designed for the system and ensures that it has less than 1% tracking error and achieves ± 1 mm stroke and 105 Hz bandwidth. The counterbalance is achieved by the symmetric arrangement of two of the same FTS systems. System vibration decreased significantly from ± 3 μm to ± 0.145 μm when the counterbalance was working. Machining experiments were conducted using the FTS system on a diamond turning machine. A microstructured surface simulation model was built and information about the workpiece surface tested and collected. When the counterbalance was working, error in the machine axes decreased from micron-level to nano-level and the surface roughness of the microstructured surface was also reduced. The system achieves ± 1 mm (±0.5 mm) stroke at 30 Hz (40 Hz) with 0.35% (0.68%) tracking error during machining processes, and the depth error of the machined microstructured surface was measured at 1.4% (2.3%). |
URI: | https://bura.brunel.ac.uk/handle/2438/25080 |
DOI: | https://doi.org/10.1016/j.ymssp.2022.109063 |
ISSN: | 0888-3270 |
Other Identifiers: | 109063 |
Appears in Collections: | Dept of Mechanical and Aerospace Engineering Research Papers |
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