Analysis of characteristics of arc shape caused by intermittent cutting force and dynamic vibration in ultra-precision cutting processes

摘要

This article analyzes the phenomenon of "arc shape" in surface characteristics caused by dynamic vibration in ultra-precision machining. First, a surface simulation model is proposed based on the effect of the tool shape on the cutting profile. The accurate mapping relationship between spindle speed, feed speed, relative vibration, and the motion track of the tool tip to the workpiece profile is also established. Thereafter, the input frequency spectrum signature of an intermittent cutting force is found to be determined by the spindle speed and workpiece characteristics, and this is verified by experimental results. A phased, self-regulated mode of forced vibration caused by intermittent cutting force is then proposed, and the forming of the arc shape feature is explained. In addition, it is revealed that output vibration can be kept at a low level by adjusting the spectrum curve of the input signal.