The precision dressing of arc-diamond wheel is very hard, expensive and time-consuming because of the super-hard diamond particles and complicated geometrical shape. This paper aims to investigate the cup-wheel dressing technology to realize the high-efficiency regeneration of the arc-diamond wheel. A two-axis cup-wheel dressing technique for precision dressing arc-diamond wheel was suggested and tested. The dressing mechanism of 2-axis cup-wheel was studied. The dressing algorithm and error compensation method were further investigated to improve the dressing precision and efficiency. The experimental results show that the 2-axis cup-wheel dressing technique is valid and applicable to realize the precision dressing of arc-diamond wheel. The machined optical surface condition was apparently improved with the cup-wheel dressed diamond wheel and even became much better when the error compensation algorithm was performed on the arc-diamond wheel.
In this paper, a large-scale NC precision face grinding machine is developed. This grinding machine can be used to the
precision machining of brittle materials. The base and the machine body are independent and the whole structure is
configured as a "T" type. The vertical column is seat onto the machine body at the middle center part through a double of
precision lead rails. The grinding wheel is driven with a hydraulic dynamic and static spindle. The worktable is
supported with a novel split thin film throttle hydrostatic lead rails. Each of motion-axis of the grinding machine is
equipped with a Heidenhain absolute linear encoder, and then a closed feedback control system is formed with the
adopted Fanuc 0i-MD NC system. The machine is capable of machining extremely flat surfaces on workpiece up to
800mmx600mm. The maximums load bearing of the work table is 620Kg. Furthermore, the roughness of the machined
surfaces should be smooth (Ra<50nm-100nm), and the form accuracy less than 2μm (±1μm)/200x200mm. After the
assembly and debugging of the surface grinding machine, the worktable surface has been self-ground with 60# grinding
wheel and the form accuracy is 3μm/600mm×800mm. Then the grinding experiment was conduct on a BK7 flat optic
glass element (400mmx250mm) and a ceramic disc (Φ100mm) with 60# grinding wheel, and the measuring results show
the surface roughness and the form accuracy of the optic glass device are 0.07μm and 1.56μm/200x200mm, and these of
the ceramic disc are 0.52μm and 1.28μm respectively.
This paper presents a method for characterization and simulation of the non-axisymmetric aspheric rough surface. With this characterization procedure, simulation of the rough surface is simplified by decomposing the rough surface into two parts, which are the non-axisymmetric aspheric surface and the only rough component without the ideal surface. Then each component of the divided surface is simulated individually. The rough surface exhibits self-affinity and the fractal number <i>D</i> can be associated with any profile and is scale-invariant, and then the rough surface component is simulated with the Weierstrass-Mandelbrot fractal function. An example for simulating a non-axisymmetric and aspheric rough surface is performed and the flexibility of this characterization method is also discussed.