期刊
MICROMACHINES
卷 12, 期 4, 页码 -出版社
MDPI
DOI: 10.3390/mi12040460
关键词
high frequency; ultrasonic-assisted vibration cutting; difficult-to-machine material; spherical steel mould; ultra-precision machining
类别
资金
- Research Office from The Hong Kong Polytechnic University [RK2Z]
- State Key Laboratory of Ultra-precision Machining Technology of The Hong Kong Polytechnic University
- Son-X, Gmbh, Aachen, Germany
The study utilized high-frequency ultrasonic vibration-assisted cutting technique to machine spherical optical steel moulds, investigating the impact of various machining parameters on workpiece surface roughness through experiments. The surface morphology and roughness of machined moulds with different slope degrees were measured and analyzed, providing guidance for achieving optical quality on the whole surface of steel moulds with varying slope degrees.
Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0 degrees, 5 degrees, 10 degrees, and 15 degrees, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.
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