Generation and characterization of ultra-precision compound freeform surfaces

Lingbao Kong (Corresponding Author), Yingao Ma, Mingjun Ren, Min Xu, Chifai Cheung

Research output: Journal article publicationJournal articleAcademic researchpeer-review

11 Citations (Scopus)


Compound freeform surfaces are widely used in bionic and optical applications. The manufacturing and measurement of such surfaces are challenging due to the complex geometry with multi-scale features in a high precision level with sub-micrometer form accuracy and nanometer surface finish. This article presents a study of ultra-precision machining and characterization of compound freeform surfaces. A hybrid machining process by combining slow slide servo and fast tool servo is proposed to machine compound freeform surfaces. The machining process for this hybrid tool servo is explained, and tool path generation is presented. Then, a normal template-based matching and characterization method is proposed to evaluate such compound freeform surfaces. Experimental studies are undertaken to machine a compound freeform surface using the proposed method based on a four-axis ultra-precision machine tool. The machined compound freeform surface is also measured and characterized by the proposed analysis and characterization method. The experimental results are presented, and the machining errors for compound freeform surfaces are also discussed.

Original languageEnglish
Pages (from-to)1-12
JournalScience Progress
Issue number1
Publication statusPublished - 1 Jan 2020


  • Compound freeform
  • fast tool servo
  • hybrid tool servo
  • slow slide servo
  • surface characterization
  • ultra-precision machining

ASJC Scopus subject areas

  • General


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