Chao Lin

Chinese Academy of Sciences, Peping, Beijing, China

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Publications (4)4.52 Total impact

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    ABSTRACT: Micro-structured surfaces have received ever-increasing requirements in various fields, including optical systems, biological engineering, measurement system, and so on. Fast tool servo (FTS)-assisted ultra-precision diamond turning technique has been extensively regarded to be a very promising technology for the fabrication of the micro-structured functional surfaces with high efficiency and high surface quality. In this paper, the machining flowchart is thoroughly introduced; the key cutting parameters including tool geometry, diamond turning machine (DTM) slide carriage feedrate, and spindle speed are carefully investigated and determined to obtain optimal cutting performances during machining processes. Additionally, a novel toolpath generation method is proposed to minimize the volume of the toolpath data. Comparing with current method, the data volume generated by the new method can be significantly decreased by several times. Finally, the efficiency of the proposed cutting parameter determination method and the new toolpath generation method are verified by fabricating a typical sinusoidal grid surface.
    International Journal of Advanced Manufacturing Technology 05/2015; DOI:10.1007/s00170-015-7163-6 · 1.78 Impact Factor
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    ABSTRACT: Diamond turning assisted by fast tool servo is of high efficiency for the fabrication of freeform optics. This paper describes a long-stroke fast tool servo to obtain a large-amplitude tool motion. It has the advantage of low cost and higher stiffness and natural frequency than other flexure-based long-stroke fast tool servo systems. The fast tool servo is actuated by a voice coil motor and guided by a flexure-hinge structure. Open-loop and close-loop control tests are conducted on the testing platform. While fast tool servo system is an additional motion axis for a diamond turning machine, a tool center adjustment method is described to confirm tool center position in the machine tool coordinate system when the fast tool servo system is fixed on the diamond turning machine. Last, a sinusoidal surface is machined and the results demonstrate that the tool adjustment method is efficient and precise for a flexure-based fast tool servo system, and the fast tool servo system works well on the fabrication of freeform optics. (C) 2014 Society of Photo-Optical Instrumentation Engineers (SPIE)
    Optical Engineering 09/2014; 53(9):092005. DOI:10.1117/1.OE.53.9.092005 · 0.96 Impact Factor
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    ABSTRACT: This paper describes the development of the fast tool servo (FTS) in detail and categorizes existing FTSs according to different principles. The characteristics and differences of these FTSs have been analyzed. A flexure-based long-stroke FTS system for diamond turning is presented with displacement range of 1mm and bandwidths of 10Hz. The vertical jump is about 0.045μm, and the full stroke tracking error is less than 0.15%. A voice coil motor and a piezoelectric actuator are used as the driving elements, and two flexure hinges are developed as the guide mechanisms. The FTS utilizes a linear encoder and a capacitive sensor to measure the displacement of the tool for closed-loop control. The electromechanical design of the FTS and its motion analysis are described. Experimental tests have been carried out to verify the performance of the FTS system. This long-stroke FTS has the advantage of easy machining, high resonance frequency, and error compensation in y-axis direction. KeywordsFast tool servo–Diamond turning–Voice coil motor–Piezoelectric actuator–Flexure hinge
    International Journal of Advanced Manufacturing Technology 04/2011; 59(9):859-867. DOI:10.1007/s00170-011-3556-3 · 1.78 Impact Factor
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    ABSTRACT: The radial spiral feed of the tool and the tool nose radius compensation are taken into consideration for the tool position trajectory (TPT) generation in diamond turning of freeform optical surfaces. Using the coarse sampling and the fine interpolation, a novel approach based on singular spectrum analysis (SSA) is presented to decompose the generated TPT into a slowly varying trend and a quickly varying quasi-periodic oscillation. The numerical experiments of the TPT decomposition of toroidal surfaces have been carried out. The results verify that the proposed approach is very effective for the TPT decomposition.
    03/2010; 97-101:2032-2035. DOI:10.4028/www.scientific.net/AMR.97-101.2032