Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review.

Chunlei He,Wenjun Zong

doi:10.3390/mi10050288

Abstract

In this work, the influencing factors and corresponding theoretical models for the surface topography in diamond turning process are reviewed. The surface profile on one tool feed is the elementary unit of surface topography. The influences coupled with the models of the duplication effect of the tool edge profile, material spring back, and plastic side flow are outlined in this part. In light of the surface profile on one tool feed and “trim principle”, the modeling methods of surface topography along the radial direction (2D surface topography) are commented. Moreover, the influence of the vibration between the diamond tool and workpiece on the 2D surface topography is discussed, and the theoretical models are summarized. Finally, the issues for modeling of 3D surface topography, particularly the influences of material defects, are analyzed. According to the state-of-the-art surface topography model of the diamond turned component, future work in this field is therefore predicted.

Highlights

Single-point diamond turning technology is extensively employed in the advanced manufacturing process, such as the fabrication of optics components and the critical parts in the aerospace technology and clean energy [1,2,3,4]
This work aims to give a comprehensive understanding of the influencing factors and corresponding modeling methods for the surface topography of the diamond turned component and discover the future developments in the related field
(1) For the surface profile model corresponding to one feed, in addition to the known factors, such as feed rate per revolution and tool corner nose radius, the tool edge waviness and material dependent factors including the material spring back and material plastic side flow should be given enough attention

Summary

Introduction

Single-point diamond turning technology is extensively employed in the advanced manufacturing process, such as the fabrication of optics components and the critical parts in the aerospace technology and clean energy [1,2,3,4]. The surface profile model in relation to one feed rate is analyzed and the corresponding models with the influencing factors in this spatial dimensional, such as tool edge waviness, material spring back and plastic side flow are presented. Wwhheerree eeiissaacocorrrercetcct oceoffiefcfiiecnietnctocnosnidseidrienrgintghethinefliuneflnuceenocfesotrfasintrgairnadgierandt isetnretnsgttrhenengitnhgeneiffnegcteofffewctoorkf wmoartkermialat[e4r6i]a.l [46] He et al established the calculation model responsible for the height value in relation to material plastic side flow at the margin point in one feed, which takes feed rate, tool corner nose radius, minimum undeformed chip thickness and effective cutting width into consideration [25]. In the future study, the combination of theoretical simulation and experimental observation should be simultaneously employed in the analysis of height component in relation to the material spring back and plastic side flow. Xu et al has theoretically noted that the shape of the cutting edge shape affects the stagnation region, chip formation and cutting forces, etc., which should be further clarified by the actual cutting experiments [61]

Surface Topography in the Radial Direction

Future Work

Conclusions