Study on surface perturbation cutting technology based on arc tool with radius offset
Two issues occur in the machining of planar perturbation structures with a sharp tool,one is that the surface quality is bad,the other is that the sharp angle on the top of the tool is easy to wear.The forma-tion mechanism of profile error and the characteristic of difficult compensation in cutting surface perturbation structure by sharp tool are systematically analyzed.It reveals that the profile error of the structure is directly proportional to the width of the tool tip and the ratio of the perturbation structure.This resulted error is diffi-cult to improve by compensate processing.Therefore,a method is proposed to reduce the cutting profile er-ror of the perturbation structure by using the arc tool combined with the tool radius compensation.The ex-periment results show that the arc tool combined with the radius compensation method has a significant effect on improving the contour accuracy of the perturbation structure.The surface quality and contour precision of the surface obtained are better than those of cutting by sharp tool.For the sample with the amplitude and pe-riod of perturbation patterns being respectively 4 μm and 60 μm,the Ra value of the surface roughness is re-duced from 59.66 nm(using sharp cutting tool)to 21 nm(using arc cutting tool),and the value of the profile error is decreased by 20%.
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