A Study of High-precision Machining of Miniature Balls with a First-order Discontinuous Self-rotation Technique

doi:10.3901/JME.2025.19.352

Abstract

Abstract: In order to achieve high-accuracy and high-precision miniature balls in batch machining, a new technique based on a first-order discontinuous self-rotation function is proposed. The technique allows the instantaneous spin axis of the miniature ball to change suddenly during the machining process, which causes the lapping trajectory of the miniature ball to repeat non-periodically and expand. Thus, the precision of miniature balls can be quickly converged in batch machining. On this basis, a geometric kinematics model of the first-order discontinuous rotation function for miniature ball machining is established, and the main factors affecting the motion of miniature ball during lapping are analyzed and identified. The resulting lapping trajectory in miniature ball machining using the first-order discontinuous rotation function is then investigated through Matlab simulation. This is followed by a experimental study, which reveals that the effects of major lapping process parameters, such as lapping pressure, lapping plate speed, and lapping fluid concentration, on the roundness and deviation of the machined balls, with an attempt to optimize the process parameters. It is shows that the roundness, surface roughness and precision of the miniature balls lapped using this technique are significantly improved. After a further batch polishing process, the roundness of the miniature balls reaches 0.09-0.13 μm, and the surface roughness R_a reaches 7.8-10 nm.

Key words: first-order discontinuous self-rotation function technique, miniature balls, kinetic analysis, batch consistency

CLC Number:

TH145
TH140

Lü Xun, JIAO Ronghui, WANG Jun. A Study of High-precision Machining of Miniature Balls with a First-order Discontinuous Self-rotation Technique[J]. Journal of Mechanical Engineering, 2025, 61(19): 352-362.

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