Papers by Author: Wing Bun Lee

Abstract: The formation of tool marks in single-point diamond turning is a fundamental study of the effect of materials swelling and recovery on surface roughness on a machined surface. A series of orthogonal face cutting tests has been conducted among plate aluminum alloy, oxygen-free high conductivity copper and electroless nickel phosphorus under the same cutting conditions by the use of facet tools with different front clearance angles. The results show that the regular width of the undulating pattern in tool marks could be explained by side swelling and the micro-waviness within a tool mark is caused by burnishing and recovery.

Abstract: The aspheric VCD lens is hard to fabricate by injection moulding due to its small volume and high precision requirement. The processing conditions have critical effects on the quality of the moulded lenses. An optic lens needs precisely controlled surface contours, so determination of the processing conditions for lens moulding becomes very complicated. This study’s purpose is to investigate experimentally some effects of the moulding conditions on the form errors of injection moulded lens. An aspheric VCD lens was moulded using polymethyl methacrylate. Different combinations of moulding conditions were used focusing on moulding process parameters of the ram speed, the mould temperature, the melt temperature and the packing pressure, The predicted model of form errors was formulated by orthogonal and regression analysis. Finally, the predicted model is proven to be valid based on the residual diagnostic plots.

Abstract: Optical freeform surface requires submicrometer form accuracy and nanometer surface finish. Ultra-precision raster milling is an emerging technology in the fabrication of those surfaces in which the dynamics factors are vital to achieve the surface quality. This paper presents a theoretical dynamics model for ultra-precision raster milling. The cutting force is derived in the depth of cut (DOC) planes in the feed and raster directions. Hence, a 3D cutting force model is established. The cutting force induced deflection between tool and workpiece is determined which can be employed to analyze the influence of the deflection on the surface generation in raster milling. The dynamic model is useful for modeling of surface generation and further control of vibration between the tool and the workpiece.

Abstract: A multi-scale model is proposed to explain the effect of material induced vibration and the quantitative relation between cutting force and the surface quality from dislocations, grain orientations, cutting tools, machine tools used in the simulation of the nano-3D surface topology in single-point diamond turning. The model-based simulation system composes of several model elements which include a microplasticity model, a dynamic model and an enhanced surface topography model. The multi-scale model brings together knowledge from various disciplines to link up physical phenomenon occurring at different length scales to explain successfully the surface generation in single-point diamond turning of crystalline materials, and offers a new direction of research in ultra-precision machining.

Abstract: An accurate prediction of plastic anisotropy induced by initial texture in sheet metal forming operations depends on the constitutive models adopted. Models of engineering interest include both phenomenological formulations and crystal plasticity based on dislocation slip. In addition to the above two approaches that are commonly adopted in FE analysis, now an alternative is available which describes anisotropic behavior of polycrystalline sheet metals still by an analytic yield function to keep the computing time as low as possible but at the same time which also takes explicitly into account the crystallographic texture of the material to give a more precise description of plasticity anisotropy. However, the locus of such a yielding potential determined by constitutive coefficients upon invoking the rate-independent crystal plasticity may exhibit an unrealistic concave shape, which will make it impossible to obtain a convergent solution. To circumvent the difficulty, a detailed computation procedure is presented to calculate the constitutive coefficients based on rate-dependent crystal plasticity. The combination of the coefficients obtained with experimentally measured texture coefficients of an annealed FCC polycrystalline sheet metal will provide a complete constitutive characterization of the material. As an application of the calibrated model, the process of deep drawing by hemispherical punch is simulated, in which plastic anisotropy (earring) corresponding to typical texture type is observed, thus demonstrating the applicability of the coefficients found.

Abstract: A rate-dependent crystal plasticity constitutive model together with Marciniak- Kuczynski(M-K) approach is employed to perform numerical simulations of forming limits diagrams(FLDs). An initial imperfection in terms of a narrow band is adopted to initialize the sheet necking. Homogeneous deformations inside and outside the band are assumed and the enforcement of compatibility and equilibrium conditions is required only on the band interface. Constitutive computations are carried out on two aggregates of FCC crystal grains, with each representing one of the two zones, respectively. Taylor homogenization assumption is employed to establish the link of stress between single crystal and polycrystal, and to derive an average response of the aggregates. The same initial texture is imparted to the two aggregates and their evolutions will be traced in the necking process. Factors affecting the FLDs prediction, such as imperfection intensity, initial texture, strain rate sensitivity and crystal elasticity will be taken into account. The above procedure will be applied to an annealed aluminium alloy sheet metal

Abstract: Virtual manufacturing (VM), which primarily aimed at reducing the lead times to market and costs associated with new product development, offers various test-beds for the time-consuming and expensive physical experimentation. Since surface roughness and form accuracy play essential roles in the functional performance of the products machined with ultra-precision machining technology. An optimizer, VSPDT (virtual single point diamond turning) system was developed for the purpose of form error compensation and optimal cutting parameters selection. In this paper, the keys issues for developing VSPDT using virtual manufacturing technology were highlighted such as framework of system, virtual workpiece, virtual machining and inspection, etc. At the end of the paper, A VSPDT was developed and applied to predict and compensate the form error, select optimal cutting parameters by using a 2-axis CNC ultra-precision turning machine.

Abstract: This paper presents an integrated platform for modelling and measurement of freeform surface generation in ultra-precision raster milling. It is composed of several components which are optics design component, tool path generator, modelling system, measurement system, evaluation component, compensation component and optimization component, respectively. The research emphasizes on modelling and simulation of freeform surface generation, the prediction of the cutting performance and hence the optimization of cutting strategy in the ultra-precision raster milling of freeform surfaces. A measurement system is also proposed to carry out a fast and efficient measurement plan of freeform surfaces. Non-uniform Rational B-Spline (NURBS) will be employed for the development of the integrated platform which will meet Standard for the Exchange of Product model data (STEP).

Abstract: Ultra-precision freeform surfaces have become widely used in advanced optics manufacture. Although these surfaces can be fabricated by ultra-precision freeform machining technology with sub-micrometer form accuracy and surface finish in nanometer range, our current understanding on the evaluation of surface quality of these surfaces is still far from perfect. In this paper, a study of measurement technology for ultra-precision freeform surfaces is presented.

Abstract: Recently, the high quality and high productivity in fabrication of freeform optics has been of primary interest in manufacturing industries, such as die and mould manufacturing, aerospace part manufacturing, and so forth. However, the fabrication of freeform optics is currently expensive and vastly complex. Ultra-precision raster milling can produce non-rotational symmetric surfaces with sub-micrometric form accuracy and nanometric surface finish without the need for any subsequent post polishing. While, there is little research work focus on this kind of machining method. This paper presents a framework of a tool path generation system for freeform surface ultra-precision raster milling. This system includes model of freeform optics, tool path generator, interference monitor and an optimization model of machining parameters. The tool path generation system can generate interference free and optimal tool path for machining freeform surfaces. Some simulation results have been presented to illustrate the performance of the system.