Finite element simulation of surface roughness in diamond turning of spherical surfaces

In this paper, a 3D finite element (FE) model is proposed for the diamond turning of spherical surfaces, and the movement control subroutine in the software is developed to describe the actual movement of diamond tool. In the simulation ns, the surface roughness is evaluated by collecting and calculating the coordinates of the nodes on the topmost machined surface, and the influences of tool nose radius, depth of cut and feed rate on surface roughness are investigated. A series of experiments with the same values of tool geometry and cutting condition parameters used in FE simulations are carried out, and the experimental results agree well with the simulation results. Besides, according to the results, the influence of tool nose radius on the surface roughness is greatest followed by feed rate, and the influence of depth of cut is smallest.