Topology optimization of a dual-axial piezo-actuated fast tool servo with decoupled kinematics

Abstract

This paper presents the design and development of a novel dual-axial piezo-actuated fast tool servo (FTS) based on a four-node finite element topology optimization design method for application in diamond machining of micro/nano-structured functional surfaces. Utilizing a solid isotropic material with penalization (SIMP) approach to express and analyze topological structure, a design model for multi-performance coupling dynamic optimization was developed. This model defines the natural frequency as the objective function, with constraints on in-plane motion coupling between the input and output ports, input–output compliance, stress, and other performance indicators. By solving the optimal design variables with the method of moving asymptotes (MMA) algorithm, a multi-performance optimization design for FTS systems with fully decoupled motion was achieved. The open-loop test of prototype validates the estimated strokes with low coupling and high natural frequencies. In closed-loop testing, the results demonstrate a minimal tracking error of $\pm 0.1\text{\%}$ for the Lissajous trajectory, showcasing its precision in tracking desired trajectories for intricate micro/nano-structure formation.