Multi-scale surface simulation of the KDP crystal fly cutting machining

The paper presents a novel approach for the modeling and simulation of surface generation in the potassium dihydrogen phosphate (KDP) crystal fly cutting machining process in the macro, micro, and nano scales, in order for the evaluation specifications in different spatial frequency region. The main influential factors of surface topography in different scales are discussed and modeled by different methods. The simulations take into account all the intricate aspects of the machining process affecting the surface topography and texture formation such as the straightness of the slide, the dynamic performance of the machine tool, and the cutter profile. This method can realize the machine tool performance and machining parameter optimization by the surface prediction and detection. The numerical calculation (NC) and the finite element (FE) method are used in the macro and micro scales. Molecular dynamics (MD) simulation is used in the nano scale. Furthermore, the proposed systematic modeling approach is verified by cutting trials which provide the coincident results of the simulated surface topography.