Point cloud based tool path generation for corrective machining in ultra-precision diamond turning

The increasing demand for machining non-rotational optical surfaces requires capable and flexible cutting tool path generation methods for ultra-precision diamond turning. Furthermore, the recent interest in on-machine metrology and corrective machining requires efficient as well as accurate algorit...

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Bibliographic Details
Published inInternational journal of advanced manufacturing technology Vol. 120; no. 9-10; pp. 6891 - 6907
Main Authors Buhmann, Marco, Carelli, Erich, Egger, Christian, Frick, Klaus
Format Journal Article
LanguageEnglish
Published London Springer London 01.06.2022
Springer Nature B.V
Subjects
Algorithms
Axis movements
CAE) and Design
Computer-Aided Engineering (CAD
Cutting tool paths
Cutting tools
Diamond machining
Diamond tools
Engineering
Error analysis
Exact solutions
Industrial and Production Engineering
Mechanical Engineering
Media Management
Original Article
Turning (machining)
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Corrective machining
Ultra-precision machining
MSC code2
Tool path generation
Freeform machining
MSC code1
Diamond turning
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Summary:The increasing demand for machining non-rotational optical surfaces requires capable and flexible cutting tool path generation methods for ultra-precision diamond turning. Furthermore, the recent interest in on-machine metrology and corrective machining requires efficient as well as accurate algorithms capable to handle point cloud based surface data. In the present work, a new computation method for the tool path generation is proposed that focuses on three-axes corrective machining. It is based on the principle of defining the surface to be machined by a point cloud of given density, since surface measurement data is usually available as point cloud. Numeric approximation techniques are used to compute the surface normal vectors and calculate the resulting positions of the cutting tool path preserving a uniform radial axis motion for face turning. Investigations are performed in order to quantify the error between the calculated tool path and the exact analytical solution. The error dependencies are analyzed regarding the local surface slope and numerical parameters. Error values below 1 nm are achieved. In addition, form deviation results prove the method’s capability for corrective diamond turn machining.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-022-09033-2