Diamond machining of freeform-patterned surfaces on precision rollers

Liu, Mingyu; Cheung, Chi Fai; Feng, Xiaobing; Wang, Chunjin

Abstract

Rapid development of freeform surfaces faces the challenges of not only higher form accuracy and smoother surface finishing, but also high machining efficiency and lower manufacturing cost. Combining diamond turning and roll-to-roll embossing technologies is a promising solution to fulfil these requirements. This paper presents a generic method to design and machine freeform surfaces on precision rollers. The freeform surface designed on the flat substrate is first transferred onto the cylindrical roller surface. The freeform-patterned roller surface is then diamond turned using the toolpath generated by a purposely developed toolpath generator. With the proposed method, the complex freeform surfaces designed on flat substrate can be transferred to and precisely machined on the cylindrical roller surfaces. A cutting experiment has been conducted to demonstrate the capability of the proposed method. In the experiment, a sinusoidal surface was designed and diamond turned on a precision roller. The results demonstrate that the proposed method is accurate and effective. The proposed method provides guidance for the design and precision manufacturing of freeform-patterned surfaces on precision rollers.

Citation

Liu, M., Cheung, C. F., Feng, X., & Wang, C. (2019). Diamond machining of freeform-patterned surfaces on precision rollers. International Journal of Advanced Manufacturing Technology, 103(9-12), 4423-4431. https://doi.org/10.1007/s00170-019-03628-y

• Journal Article Type: Article
• Acceptance Date: Mar 20, 2019
• Online Publication Date: May 27, 2019
• Publication Date: May 27, 2019
• Deposit Date: Mar 25, 2019
• Publicly Available Date: May 28, 2020
• Journal: The International Journal of Advanced Manufacturing Technology
• Print ISSN: 0268-3768
• Electronic ISSN: 1433-3015
• Publisher: Springer Verlag
• Peer Reviewed: Peer Reviewed
• Volume: 103
• Issue: 9-12
• Pages: 4423-4431
• DOI: https://doi.org/10.1007/s00170-019-03628-y
• Keywords: Ultra-precision machining, Freeform patterned surfaces, Diamond turning, Roll-to-roll, Precision surface measurement
• Public URL: https://nottingham-repository.worktribe.com/output/1682409
• Publisher URL: https://link.springer.com/article/10.1007/s00170-019-03628-y
• Additional Information: This is a post-peer-review, pre-copyedit version of an article published in International Journal of Advanced Manufacturing Technology. The final authenticated version is available online at: http://dx.doi.org/10.1007/s00170-019-03628-y