The effects of spindle vibration on surface generation in ultra-precision raster milling

• A specialized model for the particular spindle vibration in UPRM is developed.
• The derived mathematical solutions reveal that the spindle vibration is impulsive response.
• The spindle vibration produces ribbon-stripe patterns and irregular patterns.

Spindle vibration has a significant influence on surface quality of ultra-precision-machined components. However, relatively few studies on the particular spindle vibration under the excitation of intermittent cutting forces in ultra-precision raster milling (UPRM) have been reported. In this study, a specialized model for an aerostatic bearing spindle under the impulsive excitation from intermittent cutting forces of UPRM is developed and its derived mathematical solutions reveal that the spindle vibration is impulsive response. The theoretical and experimental results signify that the impulsive spindle vibration produces inhomogeneous scallops forming ribbon-stripe patterns and irregular patterns like run-out on a surface of UPRM. The potential benefits for UPRM are the theoretical supports for optimization and prediction of surface generation through the optimal selection of spindle speed.

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