Effect of spindle deformation on the binderless WC cylindrical microlens array molds in ultra-precision combined grinding

• Published in: International journal of refractory metals & hard materials Vol. 122; p. 106737
• Main Authors: Zhang, Zhenzhong, Zhang, Shibo, Hao, Guangchao, Zhang, Qibu, Fu, Xiaokui, Yao, Peng
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.08.2024
• Subjects: Combined grinding; Elastic displacement; Reconstruction; Surface topography; Reconstruction; Elastic displacement; Surface topography; Combined grinding
• ISSN: 0263-4368; 2213-3917
• DOI: 10.1016/j.ijrmhm.2024.106737

In ultra-precision combined grinding, the spindle deformation caused by the grinding force and wheel gravity influences the actual grinding depth, leading to the machining accuracy of the cylindrical microlens array (CMA) molds. In this paper, a mathematical model of spindle deformation is established based on spindle stiffness and grinding force. The single-grain trajectory is set up on account of the mathematical model. The surface data of the wheels are collected, and the grains protrusion height of the wheels is reconstructed using the Johnson conversion. The morphology of the molds is simulated considering the elastic displacement deformation of the spindle. The combined grinding experiments were conducted to verify the theoretical model through the surface topography. The results show that the combined grinding strategy has little effect on the surface accuracy of the CMA molds. It was found that combined grinding improves grinding efficiency and meets surface accuracy requirements. •A mathematical model considering spindle deformation on combined grinding was established.•The simulation profile has a high degree of consistency with the experimental profile.•Combined grinding strategy can improve machine efficiency and meet the accuracy requirements.•Different material removal mechanisms appeared in the rough-fine combined grinding process.