A study on optimal compensation cutting for an aspheric surface using the Taguchi method

In this research, the optimization of compensation cutting for eliminating the residual form error of an aspheric surface using the Taguchi method was performed. Three parameters of cutting depth, revolution of work spindle, and compensation ratio were considered as control factors, and the experimental trials based on the L9(33) orthogonal array were carried out. Based on the results of analysis of variance, the most significant factor is the compensation ratio having a percentage contribution of 49.37%. Through the confirmation experiment, the rough machining accuracy of 5.81 μm could be significantly improved to 1.53 μm with an improved efficiency of 73.67%. In comparing to the accuracy of 2.60 μm obtained by one of the initial trials, the accuracy efficiency was improved to 41.15%. As presented in this study, the systematic approach to compensation cutting can be applied to various applications of meso-machining or ultraprecision machining works performed by ultraprecision machines.