Adaptive diamond texturing of micro/nano-structured surfaces enabled by hybrid control of 2D tool position and cutting force

Abstract

Vibration-assisted diamond texturing (VADT) has recently gained prominence as an effective method for producing micro- and nanostructured functional surfaces, offering considerable application potential. Despite its advantages, the accuracy of surface formation in VADT, governed by the replication of cutting trajectories, must contend with the unavoidable inaccuracies inherent in the manufacturing systems. To address this issue and enhance the process robustness, this paper firstly proposes a novel adaptive diamond texturing approach that integrates a hybrid control of the 2D tool position and cutting force to precisely track the desired material removal state. A bidirectional mapping relationship between the actual cutting trajectory and dynamic cutting force has been established, enabling real-time decoupling of the transient material removal state. Furthermore, an objective function for optimal 2D tool compensation displacement has been analytically defined to track the desired cutting force and surface topography adaptively. Experimental validations conducted on freeform and inclined surfaces demonstrate the high consistency of the textured microstructures and precise tracking of the desired material removal state and 2D cutting force. Additionally, this paper highlights the superiority of the proposed hybrid control approach over conventional tool position-based and thrust force-based servo controls. This study advances the scientific understandings of the surface formation principle and the significant impacts of tool servo position and machining system errors on dynamic cutting force in VADT processes. It also explores the potential of force servo-based control methodologies to enhance process robustness, independent of manufacturing system errors and the characteristics of cutting force.