Advanced process monitoring, measurement and control for ultra-precision cutting

Ultra-precision cutting by utilizing a single point diamond tool is an important technology for fabrication of micro-structured and freeform surfaces. Since ultra-precision cutting is a complicated process in which materials are removed fast by the sharp edge of a diamond tool, in order to evaluate the cutting quality, it is necessary to monitor the cutting status such as cutting chatter or tool wear based on in-process measurement technologies. Furthermore, it is also desired to make quantitative evaluation of the machined surface in the cutting process instead of post-process measurement by commercial instruments. Among the in-process measurable parameters, cutting force and cutting temperature are significant factors that can represent the cutting status. This report introduces a variety of self-developed technologies with integrated force and temperature sensing functions. These technologies meet the needs of accurate force sensing and force servo feedback for micro and nano scale FTS assisted diamond cutting. By combining with machine learning method, intelligent monitoring, perception of ultra-precision machining status, in-process reconstruction of surface profile become possible.