Formation and solving for the micro-waves of fly-cut surface introduced by spindle error

In order to find out the formation mechanism of micro-waves on the fly-cut surface, the spindle motion error was sampled and a 3D topography simulation model was compiled. Firstly, a nano-class testing and evaluation system was established on the fly cutting machine, the displacement data was sampled and the spindle motion error was analyzed. Then a 3D surface profile topography simulation model was established to analyze the micro-waves caused by the spindle motion error. The simulated surface was compared with the measured surface to find out the error sources. Finally, the characteristics of spindle were improved by adjusting the control system of the spindle motor. The simulated 3D surface profile topography was similar to that of the measured profile, which verified that the macro-waves was caused by the undulate of the spindle speed. When the spindle characteristics was improved, the macro-waves caused by the spindle motion error almost disappeared, and the surface roughness reduced from more than 5 nm to 2 nm. It is thus concluded that the undulate of ultra-precision fly cutting machine spindle speed causes macro-waves on the work-piece surface, and the undulate spindle speed must less than 0.5 r/min.