Research on the Method of Reducing Dynamic Cutting Force in Aspheric Machining

Area of Science:

• Manufacturing Engineering
• Optical Engineering
• Materials Science

Background:

• Increasing demand for high-precision aspheric mirrors in photoelectric communication.
• Accurate prediction of dynamic cutting forces is crucial for machining parameter selection and surface quality.
• Existing models often do not fully account for workpiece shape and vibration effects.

Purpose of the Study:

• To develop a comprehensive dynamic cutting force model for aspheric mirror machining.
• To investigate the influence of cutting parameters, workpiece shape, and tool geometry on cutting forces.
• To validate the model's predictive accuracy and explore optimization strategies.

Main Methods:

• Development of a dynamic cutting-force model incorporating actual width of cut, depth of cut, shear angle, and vibration effects.
• Experimental validation using various cutting parameters and workpiece geometries.
• Analysis of workpiece shape parameters, including surface slope and radial size.
• Investigation of tool tip radius effects on cutting force fluctuations.
• Application of a novel interpolation-point planning algorithm for process optimization.

Main Results:

• The model accurately predicts average dynamic cutting force and fluctuation ranges with a controlled relative error of ~15%.
• Increased surface slope leads to more dramatic dynamic cutting force fluctuations.
• Diamond tool selection based on feed rate is critical for reducing cutting force fluctuations.
• The new interpolation-point planning algorithm demonstrated reliability and practicability in optimizing machining.

Conclusions:

• The developed dynamic cutting force model provides a reliable basis for processing high-reflectivity spherical/aspheric surfaces.
• Understanding the interplay between cutting parameters, workpiece geometry, and tool characteristics is essential for precision machining.
• The findings support the development of vibration suppression techniques and optimized machining strategies.