Diamond turning of freeform surfaces using non-zero rake angle tools

Fast tool servo and slow slide servo-based diamond turning are very important and widely used machining methods for freeform surfaces. In diamond turning of freeform surfaces, the research on tool path generation and machined surface topography prediction is generally for diamond turning processes using zero rake angle tools. But diamond turning with non-zero rake angle tools is also of great importance, for which very little research has been done on tool path planning and surface topography modeling. Therefore, based on coordinate transformations, this paper develops a new tool path generation method and discusses the tool geometry parameter selection for diamond turning utilizing non-zero rake angle tools. In addition, a new surface topography prediction model based on the actual position and orientation of the tool cutting edge is constructed for the machined surface. The machining experiments of a typical freeform surface are conducted based on the calculated tool paths and necessary critical tool geometry parameters. The measured results validate the developed tool path generation and tool geometry selection methods, and the constructed surface topography model.