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基于切削力和刀具振动分析的超精密刨削工艺制备高亮度反光器的研究

Investigation of ultra-precision planing process to fabricate high luminance retroreflector based on cutting force and tool vibration analysis.

作者信息

Jeong Ji-Young, Han Jun Sae, Kang Chung-Mo, Gwak Eun-Ji, Choi Doo-Sun, Je Tae-Jin

机构信息

Department of Nano Mechatronics Engineering, University of Science and Technology (UST), Daejeon, 34113, Republic of Korea.

Department of Nano Manufacturing Technology, Korea Institute of Machinery and Materials(KIMM), Daejeon, 34103, Republic of Korea.

出版信息

Sci Rep. 2022 May 9;12(1):7555. doi: 10.1038/s41598-022-10824-6.

DOI:10.1038/s41598-022-10824-6
PMID:35534505
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC9085888/
Abstract

In ultra-precision planing process, the analysis of the critical depth of cut (DOC) is required to reduce the edge blunt and micro burrs produced by size effect which decreases of the effective area for high luminance retroreflector. However, since the machining characteristics are different according to cutting tool shape, machining material, and cutting condition, determine of the critical DOC is difficult without a comparison of machined surfaces under various DOC measured by ultra-high resolution measuring instrument. In this study, the critical DOC was analyzed using cutting force and tool vibration signals. The specific cutting energy was calculated by cutting force and cross-sectional area to analyze the stress variation according to DOC. Also, acceleration signals were converted to frequency spectrum that analyze dominant vibrating direction of the cutting tool by variation of cutting characteristic. It was confirmed that the method of using tool vibration more effective and accurate than specific cutting energy through validation of the comparison between results from analyze of the vibration signals and direction measuring surfaces. The master mold with area of 250 mm was manufactured by applying analyzed critical DOC. In addition, the high luminance characteristic of a retroreflection film press formed by the master mold was confirmed.

摘要

在超精密刨削加工过程中，需要分析临界切削深度（DOC），以减少因尺寸效应产生的刃口钝圆和微毛刺，尺寸效应会减小高亮度反光器的有效面积。然而，由于加工特性会因刀具形状、加工材料和切削条件的不同而有所差异，因此在没有使用超高分辨率测量仪器测量各种切削深度下的加工表面进行比较的情况下，很难确定临界切削深度。在本研究中，利用切削力和刀具振动信号对临界切削深度进行了分析。通过切削力和横截面积计算比切削能，以分析切削深度变化时的应力变化。此外，将加速度信号转换为频谱，通过切削特性的变化来分析刀具的主导振动方向。通过对振动信号分析结果与方向测量表面结果的比较验证，证实了使用刀具振动的方法比使用比切削能更有效、更准确。通过应用分析得到的临界切削深度，制造了面积为250 mm的母模。此外，还证实了由该母模压制成型的反光膜具有高亮度特性。

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