Modeling of surface topography in single-point diamond turning machine

Area of Science:

• Manufacturing Engineering
• Materials Science
• Optical Engineering

Background:

• Surface roughness is critical for high-precision optical surface performance.
• Existing models for surface roughness estimation in diamond turning are limited.
• Tool-workpiece vibration is a key factor influencing surface topography.

Purpose of the Study:

• To propose a novel model for estimating surface roughness in single-point diamond turning.
• To incorporate tool-workpiece vibrations in both infeed and feeding directions.
• To improve the accuracy of surface roughness prediction for optical components.

Main Methods:

• Development of a new surface roughness estimation model.
• Inclusion of tool-cutting parameters and relative tool-workpiece vibrations.
• Experimental validation using metal materials and diamond-turned surfaces.

Main Results:

• The proposed model considers vibrations in both infeed and feeding directions.
• Experimental measurements confirm the significant contribution of feeding direction vibrations.
• Good correlation observed between the model predictions and experimental results for flat and cylindrical surfaces.

Conclusions:

• The new model provides a more comprehensive estimation of surface roughness.
• It accurately describes surface topography for various workpiece geometries.
• The model has potential for application to complex surfaces like spherical and freeform optics.