Simulation and experiment study on cutting temperature in diamond ultra-precision cutting of aluminum alloy mirror

The aluminum alloys are widely used to manufacture large mirror of infrared band optical systems because they have many advantages such as low cost, low mass density, well thermal conductivity, well plasticity and easy manufacturing. In order to imporve the machining efficiency and meet the requirements of suface error and suface roughness of large metal mirror, diamond ultra-precision cutting is used as finish machining to manufacture them. But the diamond tool wear is severe which is induce by the cutting heat and the cutting force during the cutting process. In this work, the metal cutting finit element sofeware-AdvantEdge has been used to study the cutting tempreture in diamond ultra-precision cutting of aluminum alloy, the influence rules of cutting parameters and tool geometric parameters are researched. And the diamond ultra-precesion cutting experiments were performed, the cutting temperature were detected by infrared thermal imager. The results show that the cutting speed exerts the most considerable influence on the cutting temperature, and the cutting temperature increases with an increase in the cutting speed. Although the temperature detected by the infrared thermal imager in the diamond ultra-precesion cutting experiments is lower than that obtained from the simulation of finit element method (FEM), the varied trend of the cutting temperature is the same. So the FEM simulation proves to be true.