Research on a simulation system for diamond turning of optical components with micro-structured surfaces

Ultra-precision machine with a fast tool servo (FTS) can fabricate many kinds of optical components with complex micro-structured surfaces, achieving sub-micrometer form accuracy and nanometer surface finish without any subsequent processing. However, it is difficult to meet the ultimate processing requirements only by operators' experience due to the complicate numerical control (NC) programs and various machining parameters. To verify the NC programs, guarantee the processing quality and improve the efficiency, a simulation system is established according to the real micro-structured surface turning system. This system includes cutting force model, platform movement model, fast tool servo model, spindle movement model, vibration model and the surface topography model. Then some simulation results as the motion locus of the tool tip, three-dimensional microstructure morphology and the surface roughness are obtained. By comparing the simulated and actual results, it can be seen that this system can simulate the actual processing, predict the final machining results and has the guidance meaning for the machining of the microstructured surfaces.