Study regarding the influence of process conditions on the surface topography during ultra-precision turning

During ultra-precision turning, the turned surface “copies” a large amount of turning process condition information. In this study, the path equations were combined with the turned surface topography equations, and the condition parameters were superimposed to develop theoretical surface topography models for ultra-precision turned end face, cylindrical, conical, and spherical surfaces influenced by turning condition parameters. The models were validated through a series of experiments. The turned surfaces were analyzed in the spatial frequency domain, and the corresponding relationship between the frequency information in the time domain and the spatial domain was obtained. The corresponding area power values were calculated to determine the quantitative impact of condition parameters on surface roughness. According to the calculation results, the surface roughness under the influence of process conditions was positively correlated with the amplitude of turning process condition parameters. The topography of the simulated surfaces was consistent with that of the experimental surfaces, and the trend of area power values corresponding to different turning process condition parameters in the simulated surface topography was consistent with the experimental results. It was proved that the established relational model, which determined the qualitative and quantitative influence of machining conditions on the machined surface, is tenable. This study established a mapping relationship between the machining condition parameters and their impact on surface topography, and also further provided a foundation for the digitization of ultra-precision machine tools.