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Efficient machining of ultra precise steel moulds with freeform surfaces

机译：高效加工具有自由曲面的超精密钢模

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Ultra precision diamond turning of hardened steel to produce optical quality surfaces can be realized by applying an ultrasonic assisted process. With this technology optical moulds used typically for injection moulding can be machined directly from steel without the requirement to overcoat the mould with a diamond machinable material such as Nickel Phosphor. This has both the advantage of increasing the mould tool lifetime and also reducing manufacture costs by dispensing with the relatively expensive plating process. This publication will present results we have obtained for generating free form moulds in hardened steel by means of ultrasonic assisted diamond turning with a vibration frequency of 80 kHz. To provide a baseline with which to characterize the system performance we perform plane cutting experiments on different steel alloys with different compositions. The baseline machining results provides us information on the surface roughness and on tool wear caused during machining and we relate these to material composition. Moving on to freeform surfaces, we will present a theoretical background to define the machine program parameters for generating free forms by applying slow slide servo machining techniques. A solution for optimal part generation is introduced which forms the basis for the freeform machining experiments. The entire process chain, from the raw material through to ultra precision machining is presented, with emphasis on maintaining surface alignment when moving a component from CNC pre-machining to final machining using ultrasonic assisted diamond turning. The free form moulds are qualified on the basis of the surface roughness measurements and a form error map comparing the machined surface with the originally defined surface. These experiments demonstrate the feasibility of efficient free form machining applying ultrasonic assisted diamond turning of hardened steel.
机译：通过应用超声辅助工艺，可以实现淬硬钢的超精密金刚石车削以产生光学质量的表面。利用这种技术，通常用于注塑的光学模具可以直接由钢加工而成，而无需在模具上涂覆可金刚石加工的材料（例如镍磷）。通过省去相对昂贵的电镀工艺，这既具有增加模具寿命的优点，又具有降低制造成本的优点。该出版物将介绍我们通过超声辅助金刚石车削以80 kHz的振动频率在淬硬钢中生成自由形式模具所获得的结果。为了提供表征系统性能的基准，我们对具有不同成分的不同钢合金进行了平面切削实验。基线加工结果为我们提供了有关表面粗糙度和加工过程中引起的刀具磨损的信息，并将这些信息与材料成分相关联。继续到自由曲面，我们将提供理论背景来定义通过应用慢速滑移伺服加工技术来生成自由形态的机器程序参数。介绍了用于最佳零件生成的解决方案，该解决方案构成了自由加工实验的基础。展示了从原材料到超精密加工的整个过程链，重点是在将零件从CNC预加工移动到使用超声辅助金刚石车削的最终加工时，保持表面对齐。自由曲面模具是根据表面粗糙度测量结果和将加工后的表面与原始定义的表面进行比较的形状误差图进行鉴定的。这些实验证明了使用超声辅助的淬硬钢金刚石车削进行有效的自由形式加工的可行性。

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