The ultra-precision single point diamond flycutting is an effective way for finishing potassium dihydrogen phosphate (KDP) crystals. However, the dynamic performance and motion precision of the machine tool would introduce the errors and have an adverse effect on the surface quality of elements. In this study, a significant method is presented to trace error sources by combining monitoring the rotary errors and analyzing the machined surface. On the one hand, forward recursion method is adopted. Based on the online measuring platform, the radial error, axial error and inclination error of spindle rotation can be obtained. Through the Fourier transform algorithm, the frequency information in each direction is known. Furthermore, the waviness along the feed direction is identified, which is determined by the rotation fluctuation. On the other hand, a novel method for errors tracing is presented by a reverse thinking mode based on the surface topography. The wavelet analysis is carried out along the cutting direction, and the obvious waviness appears in the 4th layer, of which the dominant frequency is 594Hz. Through the knocking test for the spindle system, the waviness error along the cutting direction is determined as the modal vibration of the spindle system.
With the aim to conveniently evaluate the abrasive worn states in precision grinding, this paper presents an image detection and evaluation function for grinding wheel’s micro-surface recovering. Any curved object have different focus level in the same image. With a fixed focus detector drived by motor, the information of abrasive height can be extracted from image sequence by focus evaluation. We propose and compared two method and find Gray-Level-Variance (GLV) have a better robustness on wheel’s surface recovering. The arithmetic works better and smoother when LULU operator is cooperated. Finally, we make a comparision between the result of GLV and ultra-depth 3D microscope in comparative section. The information of single abrasive and diamond pellets are concerned to prove the arithmetic’s validity and stability.
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