Based on the cross grind ing mode for large-diameter aspheric, a high-precision profile error compensation method by using an on-machine noncontact measuring sensor is presented to improve the manufacturing accuracy and efficiency of large and middle-diameter aspheric elements. Profile errors arising from machine motion errors and tool offset errors are obtained through the measured data from on-machine noncontact measurement. By measuring a standard flat ruler, the motion errors of the measurement sensor from the machine positioning errors is calibrated, the grinding tool setting error could be calculated according to the on-machine coordinate to achieve the grinding tool offset quick eccentricity calibration. By comparing the measured profile and the ideal profile, the normal residual error of each grinding program point was calculated, and the new compensation path was generated thereafter. The 300-mm-diameter K9 mirror was ground to verify the proposed compensation grinding method. Results indicate that the profile error was reduced from 35μm to 10μm through the tool setting error elimination during semi-finish grinding stage. Using the compensation grinding path according to the normal residual error, the profile accuracy was improved from 10μm to 4μm in fine grinding stage. It could be concluded that the proposed compensation grinding method is effective to improve profile accuracy and manufacturing efficiency for the large and middle-diameter aspheric elements.
Elements performance is greatly affected by their surface and subsurface integrity, especially for the brittle material. Prediction model of the subsurface damage would provide the insight into the grinding parameters effects and better control of them. In this paper, based on the classic brittle solid crack theory, prediction model of brittle material subsurface damage induced by brittle mode diamond grinding was established. Firstly, contact area calculation was modeled to estimate the involved grits number using the grit density. Based on the prediction model, grinding parameters effects were investigated. Finally, grinding machine stiffness, accuracy and damping coefficients were introduced to quantitatively analyze their effects towards subsurface damage. The proposed model would promote more definite control of grinding induced subsurface damage and optimal design of the grinding machine dynamic characteristics.
In order to design a online diameter measurement system for Hot-rolled seamless steel tube production line. On one hand, it can play a stimulate part in the domestic pipe measuring technique. On the other hand, it can also make our domestic hot rolled seamless steel tube enterprises gain a strong product competitiveness with low input. Through the analysis of various detection methods and techniques contrast, this paper choose a CCD camera-based online caliper system design. The system mainly includes the hardware measurement portion and the image processing section, combining with software control technology and image processing technology, which can complete online measurement of heat tube diameter. Taking into account the complexity of the actual job site situation, it can choose a relatively simple and reasonable layout. The image processing section mainly to solve the camera calibration and the application of a function in Matlab, to achieve the diameter size display directly through the algorithm to calculate the image. I build a simulation platform in the design last phase, successfully, collect images for processing, to prove the feasibility and rationality of the design and make error in less than 2%. The design successfully using photoelectric detection technology to solve real work problems
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