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

Area of Science:

• Manufacturing Engineering
• Materials Science
• Surface Metrology

Background:

• Ultra-precision grinding is vital for high-end optics and molds.
• Unbalanced wheel vibration leads to surface waviness and micro-texture defects.

Purpose of the Study:

• To develop a theoretical model for predicting micro-texture generation from unbalanced tool vibration.
• To understand and control deterministic surface micro-texture in ultra-precision grinding.

Main Methods:

• Analysis and calculation of grinding wheel trajectories with arc cutting edges.
• Development of a theoretical model and simulation of micro-texture generation.
• Experimental validation of theoretical predictions and phase shift influence.

Main Results:

• A double phase mechanism governing deterministic textural patterns was revealed.
• Phase shift was identified as a critical factor in micro-texture evolution.
• A novel tool path strategy coordinating oscillation and phase shift control was proposed and demonstrated.

Conclusions:

• Phase control in tool path planning is effective for fabricating flexible and tunable micro-texture surfaces.
• The developed model accurately predicts micro-texture generation due to unbalanced vibration.
• The proposed strategy allows for the generation of complex micro-textures, including rhombus-shaped arrays.