金刚石与磨料磨具工程2026，Vol.46Issue(4)：496-505,10.DOI:10.13394/j.cnki.jgszz.2024-0200
金刚石非圆弧刀具刃磨的关键技术研究
Research on key technologies of grinding non-circular arc diamond tools
摘要
Abstract
Objectives:Non-circular-arc diamond tools with high-precision edge profiles are critical for the ultra-precision cutting of aspheric optical microstructure arrays.During machining,the tool profile is directly replicated onto the workpiece surface,significantly impacting the surface form accuracy of the workpiece.Grinding can enhance tool profile precision,thereby improving cutting accuracy.Mechanical grinding is the simplest and most efficient method for diamond tool profiling.Currently,existing mechanical grinding approaches are typically designed for circular-arc diamond tools.In such methods,the center of the tool profile is aligned with the rotation center of the rotary axis,and external pressure is applied to ensure point contact between the grinding wheel surface and the tool.The grinding position is adjusted via rotary axis movement to ensure that machining coverage includes the entire area of the tool tip to be ground.Methods:Limitations of this scheme:Since the distance between all points on the tool profile and the slewing centre of the rotary axis is difficult to be equal everywhere,when the position of the grinding wheel and the fixed point of the tool is unchanged,it is impossible to control the profile point to always contact the wheel disc during the rotation process.Thus,the contour tip of non-circular tools cannot be effectively ground using conventional circular profile machining approaches.For the machining of diamond cutting tools with axisymmetric noncircular profile of submillimetre-scale,a linear envelope grinding method based on two-axis linkage and a computer numerical control(CNC)system design scheme are proposed.A mapping relationship between the position of the grinding wheel and the tool profile point is established.The grinding point position is adjusted via rotary axis motion,while the linear axis follows feed-direction motion to compensate for the positional offset of the tool profile point relative to the grinding wheel surface,thereby realising non-circular profile grinding.A CNC system for grinding machine tools based on programmable multi-axis motion controllers has been developed,which has realised the closed-loop control of the five-axis machine tool.Additionally,software design based on a master-slave computer architecture has been completed.Experiments are designed to test the machining results of the proposed method and CNC system.Axis position data and machining program are generated by inputting the tool tip profile parameters into the host software.These data are used to simulate and analyse the linear envelope grinding process.Results:The machining error from simulation is on the nanometer scale.Finally,a diamond tool with an approximate 0.143 mm arc tip radius is ground on this self-developed grinding equipment.Using a metallurgical microscope with special inspection software for tool tip profiles,the tool tip arc waviness is measured to have decreased from 130 nm to 40 nm.The two-axis linear envelope grinding method and the machine tool's CNC system design enable the surface accuracy of micro-noncircular cutting tools to reach tens of nanometers.Conclusions:The two-axis linkage linear envelope grinding scheme together with the self-developed five-axis CNC grinding system can achieve nanoscale surface contour precision for submillimeter axisymmetric noncircular arc diamond cutting tools.In future research,the tool profile accuracy can be further improved by optimizing the grinding process and improving the axis motion precision of the machine tool.关键词
金刚石刀具/非圆弧轮廓/超精密磨床数控系统/包络法/轮廓波纹度Key words
diamond cutting tools/noncircular profile/CNC system for ultra-precision grinding machine tool/envelope method/contour waviness分类
矿业与冶金引用本文复制引用
孔丹尼,刘凤琪,刘秀峰,杨宁,陶宇轩,荣佑民,孙守利..金刚石非圆弧刀具刃磨的关键技术研究[J].金刚石与磨料磨具工程,2026,46(4):496-505,10.基金项目
科技部国家重点研发计划青年科学家项目(2023YFB3407600,2023YFB3407300) （2023YFB3407600,2023YFB3407300）
"某装备光束系统关键器件超精密加工制造生产线"项目(J0017-2326-QT) （J0017-2326-QT）
湖北省教育厅科学研究计划(Q20233006) （Q20233006）
东莞市重点领域研发项目(20231200300072). （20231200300072）
