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Title: | Determinant of Dynamics and Interfacial Forces in Ultraprecision Machining of Optical Freeform Surface through Simulation-Based Analysis |
Authors: | Khaghani, A Ivanov, A Cheng, K |
Keywords: | micromachining;ultraprecision machining;single point diamond turning machining;interfacial forces;multi-body dynamics;optical freeform surfaces;slow tool servo |
Issue Date: | 12-Dec-2023 |
Publisher: | MDPI |
Citation: | Khaghani, A., Ivanov, A. and Cheng, K. (2023) 'Determinant of Dynamics and Interfacial Forces in Ultraprecision Machining of Optical Freeform Surface through Simulation-Based Analysis', Micromachines, 14 (12), 2228, pp. 1 - 12. doi: 10.3390/mi14122228. |
Abstract: | This study delves into the intricacies of ultraprecision machining, particularly in the context of machining optical freeform surfaces using Diamond Turning Machines (DTMs). It underscores the dynamic relationship between toolpath generation, hydrostatic bearing in DTMs, and the machining process. Central to this research is the innovative introduction of Metal Matrix Composites (MMCs) to replace the traditional materials used in designing linear bearings. This strategic substitution aims to dynamically enhance both the accuracy and the quality of the machined optical freeform surfaces. The study employs simulation-based analysis using ADAMS to investigate the interfacial cutting forces at the tooltip and workpiece surface and their impacts on the machining process. Through simulations of STS mode ultraprecision machining, the interfacial cutting forces and their relationship with changes in surface curvatures are examined. The results demonstrate that the use of MMC material leads to a significant reduction in toolpath pressure, highlighting the potential benefits of employing lightweight materials in improving the dynamic performance of the system. Additionally, the analysis of slideway joints reveals the direct influence of interfacial cutting forces on the linear slideways, emphasising the importance of understanding and controlling these forces for achieving higher-precision positioning and motion control. The comparative analysis between steel and MMC materials provides valuable insights into the effects of material properties on the system’s dynamic performance. These findings contribute to the existing body of knowledge and suggest a potential shift towards more advanced precision forms, possibly extending to pico-engineering in future systems. Ultimately, this research establishes a new standard in the field, emphasising the importance of system dynamics and interfacial forces in the evolution of precision manufacturing technologies. |
Description: | Data Availability Statement: The data in this study is unavailable due to data privacy and restrictions. |
URI: | https://bura.brunel.ac.uk/handle/2438/28333 |
DOI: | https://doi.org/10.3390/mi14122228 |
Other Identifiers: | ORCiD: Ali Khaghani https://orcid.org/0000-0003-1998-0275 ORCiD: Atanas Ivanov https://orcid.org/0000-0001-8041-4323 ORCiD: Kai Cheng https://orcid.org/0000-0001-6872-9736 2228 |
Appears in Collections: | Dept of Mechanical and Aerospace Engineering Research Papers |
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