Fly Cutting Technology For Ultra Precision Machining

This handbook covers the fly cutting technique, an ultra-precision mechanical machining technology which is regarded as the fastest and most reliable low-cost machining method to generate high quality complex surfaces. The ultra-precision raster milling provides more flexibility and suitability for freeform and structural surfaces with a uniform quality with sub-micrometric form error and nanometric surface roughness. These surfaces are widely applied into optics, medicine, biotechnology, electronics, and communications. The fundamental and latest advancing knowledge of fly-cutting technology is important for the future development and applications in ultra-precision mechanical machining technology. This book provides a good reference for fly-cutting technology in ultra-precision machining for undergraduate and postgraduate students, researchers, engineers, and postdoctoral fellow in advanced manufacturing area. It gives the audience an overview of the working principles, process mechanism, salient features, applications, and research directions of ultra-precision fly-cutting technology.

This book contains the research report of the DFG Research Unit FOR 1845 (2014-2020) of the Universities of Bremen and Hannover. The thematic focus lies on speeding up ultra-precision machining technology by following a holistic approach to high-performance cutting. This includes ultra-precision milling at high spindle speeds (>10000 rpm), precision tool setting mechanisms for multi-cutting-edge diamond milling tools, magnetic levitation technology for high velocity feed axes, and dedicated control strategies for error identification and compensation at high speeds. Furthermore, automation and measurement aspects of the machine setup process especially for precision balancing of the spindle rotors are presented. Finally, it is demonstrated that how the developed technologies may be integrated into a common machine tool setup. The target audience primarily comprises research experts and practitioners in production engineering, but the book may also be of interest to graduate students alike.

Ultra-precision machining is a promising solution for achieving excellent machined surface quality and sophisticated micro/nano-structures that influence the applications of components and devices. Further, given the ultrathin layer of material removed, it is a highly coupled process between cutting tool and material. In this book, scientists in the fields of mechanical engineering and materials science from China, Ukraine, Japan, Singapore present their latest research findings regarding the simulation and experiment of material-oriented ultra-precision machining. Covering various machining methods (cutting, grinding, polishing, ion beam and laser machining) and materials (metal, semiconductor and hard-brittle ceramics), it mainly focuses on the evaluation of the fundamental mechanisms and their implementation in processing optimization for different materials. It is of significant theoretical and practical value for guiding the fabrication of ultra-smooth and functional surfaces using ultra-precision machining.

Modeling and machining are two terms closely related. The benefits of the application of modeling on machining are well known. The advances in technology call for the use of more sophisticated machining methods for the production of high-end components. In turn, more complex, more suitable, and reliable modeling methods are required. This book pertains to machining and modeling, but focuses on the special aspects of both. Many researchers in academia and industry, who are looking for ways to refine their work, make it more detailed, increase their accuracy and reliability, or implement new features, will gain access to knowledge in this book that is very scare to find elsewhere.

This book presents an in-depth study and elucidation on the mechanisms of the micro-cutting process, with particular emphasis and a novel viewpoint on materials characterization and its influences on ultra-precision machining. Ultra-precision single point diamond turning is a key technology in the manufacture of mechanical, optical and opto-electronics components with a surface roughness of a few nanometers and form accuracy in the sub-micrometric range. In the context of subtractive manufacturing, ultra-precision diamond turning is based on the pillars of materials science, machine tools, modeling and simulation technologies, etc., making the study of such machining processes intrinsically interdisciplinary. However, in contrast to the substantial advances that have been achieved in machine design, laser metrology and control systems, relatively little research has been conducted on the material behavior and its effects on surface finish, such as the material anisotropy of crystalline materials. The feature of the significantly reduced depth of cut on the order of a few micrometers or less, which is much smaller than the average grain size of work-piece materials, unavoidably means that conventional metal cutting theories can only be of limited value in the investigation of the mechanisms at work in micro-cutting processes in ultra-precision diamond turning.

Volume is indexed by Thomson Reuters CPCI-S (WoS). These 189 conference papers cover a wide variety of topical areas, including: high-precision machining, non-conventional machining, CAD/CAM technology, machine tools and control, MEMS/NEMS, precision/medical devices, mechatronics, mechanical design and tribology, metrology, green manufacturing, advanced molding and forming and other related technologies. This work will certainly stimulate further research and development in the field of precision engineering.

The collection covers selected, peer reviewed papers from the 2012 International Conference on Engineering Materials, Geotechnical Engineering and Environmental Engineering (EMGEEE 2012), October 26-28, 2012, Shijiazhuang, Hebei, China. The papers are grouped as follows: Chapter 1: Advanced Technologies in Materials Science and Chemical Engineering; Chapter 2: Biochemistry and Microbiology; Chapter 3: Geotechnical Engineering; Chapter 4: Applied Mechanics and Advances in Mechanical Engineering; Chapter 5: Power Engineering; Chapter 6: Technologies of Control and Measurement. Industrial Electronics; Chapter 7: Networks and Information Technologies. Applied Methods of Computing; Chapter 8: Engineering Management and Environmental Engineering.

These contributions to the 3rd IPAS'2006 seminar are grouped in 6 sections. Part 1 reviews new techniques for handling and feeding micro parts. Micro-robotics and robot applications for micro assembly are discussed in Part 2. An overview of different design and planning applications for microassembly is provided in Part 3. Part 4 covers reconfigurable and modular micro assembly systems and control applications. The economic aspects of microassembly including new business models are discussed in Part 5 while Part 6 presents specific technical solutions and microassembly applications.