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Investigations on process vibrations and forces and their effects on resulting optical component qualities in a CNC grinding process
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Investigations on process vibrations and forces and their effects on resulting optical component qualities in a CNC grinding process
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Journal Article
Investigations on process vibrations and forces and their effects on resulting optical component qualities in a CNC grinding process
2025
Overview
The presented investigations deal with the real-time evaluation and recording of vibrations and forces during a CNC grinding process as well as the analysis and control of process influences on the surface quality of optical components. The experiments were performed on a 5-axis CNC machine and monitored using a laser vibrometer and a dynamometer. The subsequent examination of the component surfaces and topographies is carried out with the aid of two white light interferometry systems (macroscopic and microscopic). The aim of the investigations is to record and analyze correlations between the vibrometry, force and topography measurement data in order to examine their influence on the grinding process and the resulting component quality and to examine whether in-process vibrometry and force measurements can be used to detect and predict component quality during the process. Furthermore, the influence of individual grinding parameters on the grinding forces as well as the resulting component qualities are investigated under consideration of the surface roughness. It is shown that the vibration and force data measured during the grinding process correlate to a high degree with the recorded topography data. In addition, it was possible to determine which parameters have a significant influence on the observed CNC process. The setting parameters feed speed, tool grain size, and infeed depth had the greatest influence on the roughness and also on the forces. For example, the roughness could be reduced by around 47% by using the lowest considered feed speed compared to the highest. Furthermore, the forces were significantly influenced by the ultrasonic and could be reduced by around 53% by switching it on. The results underline the importance of real-time measurement technologies for improving CNC grinding processes, as they provide critical insights into the dynamic behavior of the system and its impact on the surface quality of optical components. This research demonstrates that by understanding the correlation between process forces, vibrations, and resulting surface topographies, it is possible to develop predictive models for in-process quality assurance. Consequently, the findings pave the way for more efficient and reliable grinding processes, reducing rework rates, and production costs. The presented approach can be directly applied in high-precision manufacturing environments, contributing to advancements in the fabrication of high-quality optical systems.
Publisher
Springer London,Springer Nature B.V
