Structural design and experimental research of a micro-feed tool holder based on topology optimization

Abstract

Abstract. In the present study, a new configuration for a micro-feed tool rest driven by piezoelectric ceramics with a rigid–flexible phase is designed. The flexible driving part of the micro-feed tool rest is optimized using the topology optimization method, which not only improves the driving stiffness, resolution and structural stability but also increases the maximum displacement. The structural stiffness achieved in finite element simulation analysis is 16.28 N µm−1, and the first natural frequency reaches 2521 Hz. A prototype of a piezoelectrically driven micro-feed tool holder and a testing platform are constructed, and the structural stiffness of the prototype is determined to be 15.53 N µm−1 via analysis and testing, resulting in an error of 4.8 % compared with the finite element simulation results. The first-order natural frequency is 2636 Hz given a resolution of 12 nm and a maximum output displacement of 12.983 µm. Compared with the double-parallel flexible hinge, the maximum stroke of the micro-feed tool holder increases by about 5.4 µm and the resolution is improved by about 50 %. The new micro-feed tool holder developed in this paper features a cross-plate-type flexible mobile guiding mechanism. Combining stiffness, maximum travel and displacement resolution, it is applicable to precision and ultra-precision machining.