Theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling

M. N. Cheng, Chi Fai Cheung, Wing Bun Lee, Suet To, L. B. Kong

Research output: Journal article publicationJournal articleAcademic researchpeer-review

47 Citations (Scopus)

Abstract

The fabrication of high-quality freeform surfaces is based on ultra-precision raster milling, which allows direct machining of the freeform surfaces with sub-micrometric form accuracy and nanometric surface finish. Ultra-precision raster milling is an emerging manufacturing technology for the fabrication of high-precision and high-quality components with a surface roughness of less than 10 nm and a form error of less than 0.2 μm without the need for any additional post-processing. Moreover, the quality of a raster milled surface is based on a proper selection of cutting conditions and cutting strategies. Due to different cutting mechanics, the process factors affecting the surface quality are more complicated, as compared with ultra-precision diamond turning and conventional milling, such as swing distance and step distance. This paper presents a theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling. Theoretical models for the prediction of surface roughness are built. An optimization system is established based on the theoretical models for the optimization of cutting conditions and cutting strategy in ultra-precision raster milling. A series of experiments have conducted and the results show that the theoretical models predict well the trend of the variation of surface roughness under different cutting conditions and cutting strategies.
Original languageEnglish
Pages (from-to)1090-1102
Number of pages13
JournalInternational Journal of Machine Tools and Manufacture
Volume48
Issue number10
DOIs
Publication statusPublished - 1 Aug 2008

Keywords

  • Cutting mechanics
  • Nano-surface generation
  • Optimization
  • Surface roughness
  • Ultra-precision machining
  • Ultra-precision raster milling

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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