Tool Path Generation for Multi-Degree-of-Freedom Fast Tool Servo Diamond Turning of Optical Freeform Surfaces

Fast tool servo diamond turning is one of the most important techniques for machining optical freeform surfaces. The tool path has a significant effect on roughness, waviness and profile errors. However, the mapping mechanism between the tool path and the surface form error is not precisely expressed. The paper presents a novel approach for modelling and simulation of the tool path generation in fast tool servo diamond turning. The approach, by analyzing scallop-height, linearization error and tool nose radius compensation, models the tool path generation process. The effects and characteristic of an optimized tool path are investigated through simulations. Experiments have been carried out to show that the model is feasible.