Theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling

Abstract The fabrication of high-quality freeform surfaces is based on ultra-precision raster milling, which allows direct machining of the freeform surfaces with sub-micrometric form accuracy and nanometric surface finish. Ultra-precision raster milling is an emerging manufacturing technology for the fabrication of high-precision and high-quality components with a surface roughness of less than 10 nm and a form error of less than 0.2 μm without the need for any additional post-processing. Moreover, the quality of a raster milled surface is based on a proper selection of cutting conditions and cutting strategies. Due to different cutting mechanics, the process factors affecting the surface quality are more complicated, as compared with ultra-precision diamond turning and conventional milling, such as swing distance and step distance. This paper presents a theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling. Theoretical models for the prediction of surface roughness are built. An optimization system is established based on the theoretical models for the optimization of cutting conditions and cutting strategy in ultra-precision raster milling. A series of experiments have conducted and the results show that the theoretical models predict well the trend of the variation of surface roughness under different cutting conditions and cutting strategies.