Diamond machining of freeform-patterned surfaces on precision rollers

Mingyu Liu, Chi Fai Cheung, Xiaobing Feng, Chunjin Wang

Research output: Journal article publicationJournal articleAcademic researchpeer-review

1 Citation (Scopus)

Abstract

Rapid development of freeform surfaces faces the challenges of not only higher form accuracy and smoother surface finishing but also high machining efficiency and lower manufacturing cost. Combining diamond turning and roll-to-roll embossing technologies is a promising solution to fulfill these requirements. This paper presents a generic method to design and machine freeform surfaces on precision rollers. The freeform surface designed on the flat substrate is first transferred onto the cylindrical roller surface. The freeform-patterned roller surface is then diamond turned using the toolpath generated by a purposely developed toolpath generator. With the proposed method, the complex freeform surfaces designed on flat substrate can be transferred to and precisely machined on the cylindrical roller surfaces. A cutting experiment has been conducted to demonstrate the capability of the proposed method. In the experiment, a sinusoidal surface was designed and diamond turned on a precision roller. The results demonstrate that the proposed method is accurate and effective. The proposed method provides guidance for the design and precision manufacturing of freeform-patterned surfaces on precision rollers.

Original languageEnglish
Pages (from-to)4423-4431
Number of pages9
JournalInternational Journal of Advanced Manufacturing Technology
Volume103
Issue number9-12
DOIs
Publication statusPublished - Aug 2019

Keywords

  • Diamond turning
  • Freeform-patterned surfaces
  • Precision surface measurement
  • Roll-to-roll
  • Ultra-precision machining

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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