Abstract
Fast tool servo (FTS) machining technology is a promising method for freeform surfaces and machining micro-nanostructure surfaces. However, limited degrees of freedom (DOF) is an inherent drawback of existing FTS technologies. In this paper, a piezo-actuated serial structure FTS system is developed to obtain translational motions along with z and x-axis directions for ultra-precision machining. In addition, the principle of the developed 2-DOF FTS is introduced and explained. A high-rigidity four-bar (HRFB) mechanism is proposed to produce motion along the z-axis direction. Additionally, through a micro-rotation motion around flexible bearing hinges (FBHs), bi-directional motions along the x-axis direction can be produced. The kinematics of the mechanism are described using a matrix-based compliance modeling (MCM) method, and then the static analysis and dynamic analysis are performed using finite element analysis (FEA). Testing experiments were conducted to investigate the actual performance of the developed system. The results show that low coupling, proper travel, and high natural frequency are obtained. Finally, a sinusoidal wavy surface is uniformly generated by the mechanism developed to demonstrate the effectiveness of the FTS system.
Highlights
Freeform surfaces have been widely used in the aerospace, military, and biomedical engineering fields [1,2,3]
Many scholars have made great efforts in many aspects including motion travel, working bandwidth, and trajectory-tracking accuracy to improve the performance of Fast tool servo (FTS) system
The input stiffness in the x-axis direction obtained by finite element analysis is 18.12 N/μm, which is a 13.09 % error compared with the theoretical value obtained by the compliant matrix method
Summary
Freeform surfaces have been widely used in the aerospace, military, and biomedical engineering fields [1,2,3]. The frequency and amplitude of the output trajectory can be adjusted flexibly during non-resonant vibration cutting operations, so this machining method provides greater flexibility in the machining of certain complex and difficult-to-machine surfaces [20,21]. Multi-DOF non-resonant vibration cutting technology mainly adopts a piezoelectric-driven parallel structure-compliant mechanism to obtain higher operating frequency and stiffness [5,24]. A FTS system with serial structure is designed, which has the characteristics of simple control and independent motion It has good flexibility, and it can extend the processing range of complex surfaces due to its active cutting motion along both the x and z-axis directions.
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