An Investigation On Generating NC Program And Predicting Surface Roughness In Fly-cutting Micro-structures

With the development of science and technology, micro-structures, which has become key parts of Photoelectricity and Optical communication, has been widespread in many fields, such as communications, aerospace, electronics and so on. The high precision, high efficiency and low cost manufacturing of micro structure arises widespread concern and research in the world. The general machining methods which is making use of some special methods such as LIGA and micro EDM process, is complicated, low efficiency,and high cost, which has greatly circumscribed the wide use of the optical microstructures. Ultra-precision fly-cutting with single crystal diamond cutting tool is an emerging manufacturing technology for the fabrication of micro structure with nano-surface finish and sub-micron form accuracy without the need for any subsequent post polishing. However, there is short of the NC program software which is adapted to ultra-precision fly-cutting with single crystal diamond cutting tool for the optical microstructure.To automatically generate the NC program software of ultra-precision fly-cutting with single crystal diamond of optical microstructures, this paper takes ultra-precision fly-cutting with single crystal diamond of optical microstructures as the object to study and make research on following aspects:According to the character of ultra-precision fly-cutting with single crystal diamond optimizing parameters of the NC machining process, scallop error and the choice of cutting method, cutting contact data and cutting location data is calculated. The right tool path is obtained through the post processing and error checking.An investigation on the effection of machining parameters on surface quality, the mathematic model of optimizing parameters is established. Precitech Freeform5-axis ultra-precision machining is used to process cutting experiments. The goal function of optimizing parameters is obtained by useing of multi-factors linear regressive method and the optimizing result is obtained.In order to produce micro v-groove in ultra-precision fly-cutting, an integrated platform using VC++is developed to design micro v-groove, data transform, build micro v-groove model, as well as, simulate and predict the surface roughness. The function of generating the tool path automatically and simulating the tool path is come true. Stability and efficiency of the system, preciseness of the NC program and validity of predicting the surface roughness are proved. The expection is achieved.