A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Abstract In recent years, research has begun to focus on the development of non-resonant elliptical vibration-assisted cutting (EVC) devices, because this technique offers good flexibility in manufacturing a wide range periodic microstructures with different wavelengths and heights. However, existing EVC devices for diamond turning can only operate at relatively low frequencies, which limits their machining efficiencies attainable microstructures. This paper concerns design performance analysis device overcome challenge operational frequency. The structural was proposed, adopting leaf spring flexure hinge (LSFH) notch prismatic joint (NHPJ) mitigate cross-axis coupling reciprocating displacements tool combine them into an trajectory. Finite element (FEA) using mapped meshing method performed assist determination key dimensional parameters hinges achieving high frequency while considering modal characteristics. impact thickness LSFH sequence vibrational mode shape also quantitatively revealed study. Moreover, reduction reduce natural device, thereby influencing upper limit its It found that decrease neck NHPJ ratio. Experimental tests were conducted systematically evaluate heat generation, coupling, characteristics tool’s trajectory prototype designed device. test results showed it could up 5 kHz. ratio generation are both acceptable level. accuracy generating heights through tuning input voltage have been demonstrated via micro-dimple arrays two-tier microstructured surfaces. High-precision obtained 1.26% 10.67% errors wavelength height, respectively.