Study on the influence of spindle vibration on the surface roughness of ultra-precision fly cutting

Spindle vibration is a key factor influencing the quality of the processed surfaces during ultra-precision fly cutting. An extremely tiny vibration will directly influence the quality of the surface at the nanoscale. Therefore, in this study, a mathematical model of aerostatic spindle vibration under pulsed excitation was established by analysing the characteristic cutting path of a fly cutter head and the state of the spindle under interrupted cutting force and then, the axial and radial of the aerostatic spindle to pulses during periodically interrupted fly cutting were calculated using a Fourier series. Under the periodic processing mode of high-speed fly cutting, a simulation and experimental analysis on the spindle vibration were conducted. The experimental results show that the cutting force and spindle speed are major factors influencing surface roughness. According to the simulation and experimental analysis, reliable theoretical guidance is provided for the improvement and prediction of surface quality of an ultra-precision fly cutting.