Surface adaptive fast axis ultra precision turning

Diamond turning is a key technology of ultra-precision machining and it is commonly used for the manufacturing of prototypes or mold inserts in growth markets of the photonic industries. A novel method for surface adaptive fast axis ultra-precision turning will be introduced in this paper. With this new approach, it will be possible to incorporate surface properties and machine dynamics for every kind of surface. In a completely digitalized control chain the CNC functionality is transferred from a classical online algorithm to an high density multicore offline operation where set point profiles for each axis are transferred with up to 10.000 Pt/s directly to the servo drive. To adapt the properties of the surface and the machine dynamics all profiles are analyzed in advance to identify critical spots and adapt the set points profiles of all axis to maximize surface quality. To prove the proposed setup an LED headlight surface will be generated and optimized within this paper.