ULTRAPRECISION MACHINING OF HYBRID FREEFORM SURFACES USING MULTIPLE-AXIS DIAMOND TURNING

Abstract

This dissertation presents four comprehensive studies which have been conducted for seamless ultraprecision multiple-axis machining of hybrid freeform surfaces. Firstly, a hybrid fast tool/slow slide servo (FTS/SSS) diamond turning incorporates with both FTS and SSS systems to address the FTS stroke length range and the low bandwidth of SSS system. Secondly, a developed automated Guilloche machining technique addresses the difficulties of fabricating hybrid freeform surfaces in a single process, by increasing the number of machining axes to overcome the loss of symmetry. Thirdly, a novel surface analytical model has been derived to pre-evaluate the cutting linearization errors and also optimizes the number of cutting points of spiral tool trajectory. Lastly, a comprehensive CAD/CAM software solution has also been developed for the manufacture of hybrid freeform surface. Therefore, a comprehensive and integrated CAD/CAM software solution has been validated by the succession of machined freeform surfaces with good quality and accuracy.