Design and testing of a long-range, precision fast tool servo system for diamond turning

A long-range, precision fast tool servo (FTS) system was developed that is capable of accurately translating the cutting tool on a diamond turning machine (DTM) with maximum accelerations of 260 m s−2 and bandwidths of up to 140 Hz. The maximum displacement range of the cutting tool is 2 mm. The FTS utilizes a flexure mechanism driven by a voice coil actuator, a custom linear current amplifier and a laser interferometer feedback system. This paper describes the design of the electromechanical system, controller configuration and cutting tests to evaluate the system. Initially, low disturbance rejection and poor command following degraded the surface finish of machined test parts. Several techniques to add damping to the dynamic system were investigated to improve the generated surface finishes. Electromotive damping was applied inside the voice coil actuator, and two different viscoelastic damping materials were applied to the flexure mechanism. A control strategy consisting of linear and non-linear feedforward controllers and a proportional, integral and derivative (PID) feedback controller was implemented to accommodate the changed system dynamics. The workpieces were analyzed using form and surface inspection instruments to evaluate the overall system performance. A cylindrical part with five lobes cut across the face had a surface finish value between 20 and 30 nm Ra.