Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning
Ultra-high-precision single-point diamond turning (SPDT) is the state-of-the-art machining technology for the advanced manufacturing of critical components with an optical surface finish and surface roughness down to one nanometer. One of the critical factors that directly affects the quality of the...
| Main Authors: | , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2023-09-01
|
| Series: | Micromachines |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2072-666X/14/10/1857 |
| _version_ | 1797572896618446848 |
|---|---|
| author | Shahrokh Hatefi Farouk Smith |
| author_facet | Shahrokh Hatefi Farouk Smith |
| author_sort | Shahrokh Hatefi |
| collection | DOAJ |
| description | Ultra-high-precision single-point diamond turning (SPDT) is the state-of-the-art machining technology for the advanced manufacturing of critical components with an optical surface finish and surface roughness down to one nanometer. One of the critical factors that directly affects the quality of the diamond-cutting process is the cutting force. Increasing the cutting force can induce tool wear, increase the cutting temperature, and amplify the positioning errors of the diamond tool caused by the applied cutting force. It is important to measure the cutting force during the SPDT process to monitor the tool wear and surface defects in real time. By measuring the cutting force in different cutting conditions, the optimum cutting parameters can be determined and the best surface accuracies with minimum surface roughness can be achieved. In this study a smart cutting tool for in-process force measurement and nanopositioning of the cutting tool for compensating the displacements of the diamond tool during the cutting process is designed and analyzed. The proposed smart cutting tool can measure applied forces to the diamond tool and correct the nanometric positioning displacements of the diamond tool in three dimensions. The proposed cutting tool is wireless and can be used in hybrid and intelligent SPDT platforms to achieve the best results in terms of optical surface finish. The simulation results are shown to be almost consistent with the results of the derived analytical model. The preliminary results pave the way for promising applications of the proposed smart cutting tool in SPDT applications in the future. |
| first_indexed | 2024-03-10T21:02:12Z |
| format | Article |
| id | doaj.art-02c92d6c7dbd403c92422192f4a2c6af |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-10T21:02:12Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-02c92d6c7dbd403c92422192f4a2c6af2023-11-19T17:23:51ZengMDPI AGMicromachines2072-666X2023-09-011410185710.3390/mi14101857Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond TurningShahrokh Hatefi0Farouk Smith1Department of Mechatronics, Faculty of Engineering, the Built Environment and Technology, Nelson Mandela University, Port Elizabeth 6000, South AfricaDepartment of Mechatronics, Faculty of Engineering, the Built Environment and Technology, Nelson Mandela University, Port Elizabeth 6000, South AfricaUltra-high-precision single-point diamond turning (SPDT) is the state-of-the-art machining technology for the advanced manufacturing of critical components with an optical surface finish and surface roughness down to one nanometer. One of the critical factors that directly affects the quality of the diamond-cutting process is the cutting force. Increasing the cutting force can induce tool wear, increase the cutting temperature, and amplify the positioning errors of the diamond tool caused by the applied cutting force. It is important to measure the cutting force during the SPDT process to monitor the tool wear and surface defects in real time. By measuring the cutting force in different cutting conditions, the optimum cutting parameters can be determined and the best surface accuracies with minimum surface roughness can be achieved. In this study a smart cutting tool for in-process force measurement and nanopositioning of the cutting tool for compensating the displacements of the diamond tool during the cutting process is designed and analyzed. The proposed smart cutting tool can measure applied forces to the diamond tool and correct the nanometric positioning displacements of the diamond tool in three dimensions. The proposed cutting tool is wireless and can be used in hybrid and intelligent SPDT platforms to achieve the best results in terms of optical surface finish. The simulation results are shown to be almost consistent with the results of the derived analytical model. The preliminary results pave the way for promising applications of the proposed smart cutting tool in SPDT applications in the future.https://www.mdpi.com/2072-666X/14/10/1857on-machine metrologyin-process metrologyhybrid machiningultra-precision manufacturingcutting force measurementtool nanopositioning |
| spellingShingle | Shahrokh Hatefi Farouk Smith Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning Micromachines on-machine metrology in-process metrology hybrid machining ultra-precision manufacturing cutting force measurement tool nanopositioning |
| title | Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning |
| title_full | Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning |
| title_fullStr | Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning |
| title_full_unstemmed | Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning |
| title_short | Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning |
| title_sort | design and analysis of ultra precision smart cutting tool for in process force measurement and tool nanopositioning in ultra high precision single point diamond turning |
| topic | on-machine metrology in-process metrology hybrid machining ultra-precision manufacturing cutting force measurement tool nanopositioning |
| url | https://www.mdpi.com/2072-666X/14/10/1857 |
| work_keys_str_mv | AT shahrokhhatefi designandanalysisofultraprecisionsmartcuttingtoolforinprocessforcemeasurementandtoolnanopositioninginultrahighprecisionsinglepointdiamondturning AT farouksmith designandanalysisofultraprecisionsmartcuttingtoolforinprocessforcemeasurementandtoolnanopositioninginultrahighprecisionsinglepointdiamondturning |