Theoretical modeling and machining experiments of cylindrical microstructure assisted by single-point diamond turning

Microstructure requires nanometer-scale surface roughness and micro- or even sub-micron form error accuracy in different applications. Two kinds of modeling theories and methods of micro-feature of rotating body and non-rotating body are studied, and the corresponding tool turning trajectory planning method is put forward. In order to process the designed micro-feature structure successfully and avoid the interference and overcutting between tool and workpiece caused by improper selection of tool parameters, the cutting parameters are analyzed and two error theories are proposed. Then, a precision-driven turning trajectory planning method is obtained, which can optimize the trajectory by adjusting turning parameters according to the setting errors. The experiments are carried out to verify the proposed theories, and the results of measurements are that the surface roughness and surface form accuracy of the cylindrical sine wave groove micro-feature surface are 0.1714 μm and 1.32 μm, respectively. The surface roughness and surface form accuracy of the cylindrical sinusoidal mesh micro-feature surface are 0.1625 μm and 1.8 μm, respectively. The results meet expectations and verify the reliability of the error theory and the trajectory optimization theory.