Mr. Bin Zhang Profile

Bin Zhang

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Proceedings Article | 29 December 2023 Paper

Research on the influence of low frequency forced vibration on the surface quality of optical elements in ultra precision turning

Yang Zhang, Bin Zhang, Hongxin Zhao, Hailiang Wu

Proceedings Volume 12976, 1297626 (2023) https://doi.org/10.1117/12.3009623

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Ultra precision turning technology is widely used in the manufacturing of optical precision components due to its excellent machining accuracy and production efficiency. In the actual turning process, various types of vibrations are superimposed and manifested as relative vibrations between the tool and the workpiece, resulting in specific shape texture features on the surface of the workpiece, seriously affecting the surface quality of the workpiece and reducing its efficiency. This article analyzes the impact of unfiltered low-frequency vibration in the ultra precision machining process environment on the machined surface morphology, achieving vibration error tracing based on workpiece surface morphology data analysis and texture features, and further improving the surface quality of ultra precision turning workpieces. A simulation model for ultra precision turning surface morphology was established based on the principle of tool contour mapping, taking into account the relative vibration in the circumferential, axial, and radial directions between the tool and the workpiece. Based on the deterministic and random factors obtained, the morphology prediction simulation was carried out in the model. Based on the comparative experimental method, single factor experimental method, and result oriented principle, the effect of different cutting parameters on the surface quality of the workpiece under the influence of low-frequency vibration was analyzed. The simulation results were compared with the actual surface morphology, and it was found that the simulation results had consistent layout rules with the measured morphology images. This study provides a reference for the establishment of ultra precision cutting models under external low-frequency forced vibration.

Proceedings Article | 9 January 2023 Paper

Research on the high-quality, low-wear single point diamond turning process of single crystal germanium

Hongxin Zhao, Bin Zhang, Shanyi Ma, Deqing Zhu

Proceedings Volume 12507, 1250716 (2023) https://doi.org/10.1117/12.2655442

KEYWORDS: Germanium, Crystals, Spindles, Single point diamond turning, Surface roughness, Surface finishing, Optical components, Diamond machining, Infrared radiation, Optics manufacturing

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Single crystal germanium, which is a typical infrared optical crystal used for aerospace and astronomy applications due to their excellent mechanical, optical, and chemical property is difficult to obtain super smooth surface in ultra-precision turning and easy to cause tool wear owing to its inherent brittleness and hardness. In the processing process of single crystal germanium optical elements, good surface roughness is beneficial to improve the diffraction efficiency of single crystal germanium, while small cutting force can effectively lower the diamond tool wear caused by high hardness of germanium. In this paper, the single variable method is used to study the influence of the main factors in the single point diamond turning process on the surface roughness and cutting force of single crystal germanium, including spindle speed back cutting depth and feed. The experimental results are used to guide the machining process of the single crystal germanium diffraction surface, and the appropriate process parameters are selected to perform ultra-precision turning on the single crystal germanium with a very small cutting force to obtain a sub-nanometer ultra-smooth surface to improve the diffraction efficiency and reducing tool wear.

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