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FTS turbo Development

This project focuses on the development of a high-speed fast tool servo for diamond turning, targeting operational capability at 10 kHz or higher with a 5 mm stroke (P-V). The first Fast Tool Servo (FTS) achieved a 20 mm stroke at 2 kHz, while previous Ultramill models operated at 500 Hz and 5 kHz. Key challenges include actuator selection, structural design, heat generation management, control system development, and machining experiments. The outcome is a compact design capable of 10 kHz with a closed-loop feedback system ensuring optimal performance and dynamic values.

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FTS turbo Development

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  1. FTSturbo Development By Nathan Buescher November 7, 2003

  2. Objectives • Build high-speed fast tool servo for diamond turning • Operate at 10 KHz or greater • 5 mm stroke ( P-V )

  3. Background • 1st FTS : 20 mm stroke, 2 KHz bandwidth

  4. Background • Ultramill I (500 Hz) and II (5 KHz)

  5. Work Plan and Technical Challenges • 1. Actuator selection • Shorter, stiffer piezo stack • Geometry • Reduced hysteresis materials

  6. Work Plan and Technical Challenges • 2. Structural Design • Small, lightweight moving mass/tool holder • Preload and flexures • Capacitance gauge orientation

  7. Work Plan and Technical Challenges • Examples

  8. Work Plan and Technical Challenges • 3. Heat Generation • Fluid Cooling system • Reduced hysteresis  Air-cooled

  9. Work Plan and Technical Challenges • 4. Control System Development • System model • Frequency Response  Transfer fcn • PID or pole placement control

  10. Work Plan and Technical Challenges • Example of Closed-Loop control scheme

  11. Work Plan and Technical Challenges • 5. Machining Experiments • Cutting error and surface shapes evaluated • Dynamic response (overshoot, rise time, etc) • Test wide range of frequencies and spindle speeds

  12. Results • 5 mm stroke with bandwidth of 10 KHz • Small, compact design with maximized component life • Closed loop feedback system with acceptable dynamic values

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