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

Chen, Shanshan; Yang, Shuming; Liao, Zhirong; Fai Cheung, Chi Fai; Jiang, Zhuangde; Zhang, Feihu

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.

Citation

Chen, S., Yang, S., Liao, Z., Fai Cheung, C. F., Jiang, Z., & Zhang, F. (2022). Study of deterministic surface micro-texture generation in ultra-precision grinding considering wheel oscillation. Optics Express, 30(4), 5329-5346. https://doi.org/10.1364/OE.452751

• Journal Article Type: Article
• Acceptance Date: Jan 27, 2022
• Online Publication Date: Feb 3, 2022
• Publication Date: Feb 14, 2022
• Deposit Date: May 11, 2023
• Publicly Available Date: May 26, 2023
• Journal: Optics Express
• Electronic ISSN: 1094-4087
• Publisher: Optical Society of America
• Peer Reviewed: Peer Reviewed
• Volume: 30
• Issue: 4
• Pages: 5329-5346
• DOI: https://doi.org/10.1364/OE.452751
• Public URL: https://nottingham-repository.worktribe.com/output/7508871
• Publisher URL: https://opg.optica.org/oe/fulltext.cfm?uri=oe-30-4-5329&id=469155