Theoretical and experimental investigation on modeling of surface topography influenced by the tool-workpiece vibration in the cutting direction and feeding direction in single-point diamond turning.

The fabrication of high-quality freeform surfaces is based on ultra-precision diamond turning with fast tool servo (FTS) technology which allows direct machining of the freeform surfaces with sub-micrometric form accuracy and nanometric surface roughness. Surface roughness is an important factor in evaluating the performance of the optical freeform surfaces. This paper presents a theoretical and experimental analysis of surface generation in ultra-precision single-point diamond turning. In this model, we take into consideration the basic machining parameters as well as the relative vibration between the workpiece and the tool in both the cutting and feeding directions. Theoretical model is built to predicting the surface roughness of machined flat surface as well as freeform surfaces. A series of experiments have conducted and the results show good correlation between the theoretical model and the fabricated surfaces. [ABSTRACT FROM AUTHOR]