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Free-form surface machining strategy and shape error correction method based on slow tool servo turning
Applied Optics
|August 12, 2025
Summary
This study introduces a novel free-form surface machining strategy using slow tool servo technology to correct shape errors. The method significantly enhances machining accuracy by iteratively aligning measured and theoretical surfaces, reducing errors effectively.
Area of Science:
- Manufacturing Engineering
- Precision Engineering
- Surface Metrology
Background:
- Machining quality of free-form surfaces is often limited by measurement accuracy.
- Convergent shape errors in free-form surface machining present significant challenges.
- Accurate compensation strategies are crucial for high-precision manufacturing.
Purpose of the Study:
- To investigate a free-form surface machining strategy incorporating slow tool servo technology.
- To develop and validate a shape error correction method for free-form surfaces.
- To improve the overall machining accuracy of complex surfaces.
Main Methods:
- An iterative accuracy-adjusted surface matching measurement strategy was developed.
- Improved combined Combined Principal Direction (CPD) and Iterative Closest Point (ICP) algorithms were utilized.
- Translational and rotational coordinate transformations were employed for surface alignment.
Main Results:
- The proposed method accurately obtains surface shape errors after single-point diamond turning.
- Continuous convergence of shape errors was observed after iterative compensation.
- Peak-to-Valley (PV) error reduced from 2.01µm to 765nm; Root Mean Square (RMS) error decreased from 271nm to 188nm.
Conclusions:
- The effectiveness of the proposed compensation method for free-form surfaces is verified.
- The strategy significantly improves machining accuracy and reduces shape errors.
- This approach offers a viable solution for high-precision free-form surface manufacturing.
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