Study of deterministic surface micro-texture generation in ultra-precision grinding considering wheel oscillation

Author:

Chen Shanshan12,Yang Shuming1,Liao Zhirong,Cheung Chi Fai3ORCID,Jiang Zhuangde1,Zhang Feihu4

Affiliation:

1. Xi'an Jiaotong University

2. Research Institute of Xi’an Jiaotong University

3. The Hong Kong Polytechnic University

4. Harbin Institute of Technology

Abstract

Ultra-precision grinding is crucial for manufacturing high-end optics and molds, while the unbalanced wheel vibration is inevitable and becomes even more critical in surface generation, which resulted in undesired waviness and micro-texture on the ground surface. In this paper, to understand and control the micro-texture generation, a theoretical model has been developed to predict the deterministic surface micro-texture generation resulted from unbalanced tool vibration in ultra-precision grinding, in which the overlap trajectories of grinding wheel with an arc cutting edge were analyzed and calculated. The simulation work was performed and a double phase mechanism involved in deterministic textural pattern and structure has been revealed. Both theoretical and experimental results proved that phase shift is an important factor to determine micro-texture evolution in the ultra-precision grinding process. On this basis, a novel tool path strategy has been proposed to fabricate deterministic micro-structure by coordinating oscillation motion of the grinding wheel and phase shift control, in which a rhombus-shaped micro-structure array can be generated. A small adjustment for the phase shift was conducted and it was found that the more complex micro-texture with different textural patterns and micro-structure can be machined. The results indicated that the phase control for the tool path planning is an effective method to fabricate flexible and tunable micro-texture surfaces in ultra-precision grinding.

Funder

National Natural Science Foundation of China

China Postdoctoral Science Foundation

Natural Science Foundation of Zhejiang Province

Scientific Research and development plan for Beilin District (Xi'an city, Shaanxi Province) 2020

China Scholarship Council

Hong Kong Polytechnic University

Publisher

Optica Publishing Group

Subject

Atomic and Molecular Physics, and Optics

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