Technological Features of Forming Flat Tool for Processing Axicons

It has been substantiated that in order to control the process of forming flat surfaces while using a free grinding method it is advisable to choose such machine setup parameters as a tool diameter and its rotation frequency, an amplitude of the reciprocating movement of the part along the tool (or vice versa) and frequency of this movement, as well as the value of  the working  force.  Mathematical  modeling  of  patterns  for abrasive processing of  flat surfaces in the conditions of  free grinding on lever machines has been carried out in the paper. A formula has been obtained for calculating a sliding speed at selected reference points on the surface to be treated while taking into account the pressure in their vicinity. Patterns of the part operation have been determined, for which a correct plate is used in the proposed axicon production technology with due account of the combination and size of the selected setup parameters for processing equipment. Self-organization of the processing process has been substantiated while using a free grinding method. Sensitivity of a kinematic response to a change in processing modes and efficiency of these modes in terms of process performance have been determined in the paper. It has been noted that an increase in a tool diameter, as one of the effective adjustment parameters for controlling the shaping process, is difficult to implement in practice, since this requires replacement of tools, each of which must be pre-configured while using a special rather time-consuming technique. The paper reveals that with an increase in the tool rotation frequency  and an amplitude of its oscillatory movements, there is an increased removal of material on the periphery of the surface being machined, and with an increase in  vibrational movements, on the contrary, the central zone of the part is more intensively activated.

axicon, free grinding, deflection arrow, shaping, abrasive processing, sensitivity parameter, actuator

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