A generalized dynamic model for spindle vibration influencing surface topography in different ultra-precision machining processes

Ultra-precision machining (UPM) typically involves ultra-precision diamond turning (UPDT), ultra-precision raster milling (UPRM), and ultra-precision grinding (UPG). In UPM, spindle vibration (SV) is a natural feature majorly influencing surface topography. In this paper, a dynamic model for SV was generalized to study its distinctive effects on surface topography in different UPM processes. The theoretical results were identified well by a series of cutting tests. In UPDT, constant cutting forces induce harmonic SV to produce regular patterns. In UPRM, periodical impulsive cutting forces cause periodical impulsive SV to generate quasi-regular patterns. In UPG, random impulsive cutting forces result in partially random impulsive SV to form partially random patterns. The generalized model can be employed to predict the effects of SV on surface generation in UPM.