An investigation into surface generation in ultra-precision raster milling

This paper presents a study of the factors that affect surface generation in ultra-precision raster milling. A series of experiments was conducted to study the effect of different factors on surface generation in ultra-precision raster milling. The results indicate that machining parameters, tool geometry, cutting strategy, and tool wear are the critical factors for achieving super mirror finish surfaces, while cutting strategies, tool path generation, and kinematic errors of the slides are vital to the form accuracy of freeform surfaces. The experimental results are useful for the diagnosis of systematic errors in machine tools, and the control of machining errors. Compensation strategies can be devised, and improvement can be made in the optimization of surface generation and hence the surface quality when using ultra-precision raster milling can be improved.