Modeling and prediction of surface topography with three tool-work vibration components in single-point diamond turning

In single-point diamond turning (SPDT), the relative vibration between the tool and the workpiece plays an important role in the surface generation, therefore affecting the achieved surface quality. In this paper, a surface roughness prediction model is developed under the synthetically consideration of the influences of tool-work vibration components in feeding, cutting and infeed cutting directions, on surface topography in SPDT. This study makes a theoretical investigation on the effects of three vibration components on tool locus to build a modification method for the actual tool locus. Due to the existence of tool interference induced by tool-work vibrations, two judgment criterions and an iterative calculation methodology are proposed to efficiently confirm the valid tool locus points so as to make a more precise prediction on the diamond turned surface. A series of experiments are conducted to verify the surface roughness prediction model. The experimental results show that the predicted surface roughness agrees well with the measured ones. This indicates that the developed model with three direction vibrations makes a better prediction for the single diamond turned surface.