A process planning strategy for removing arbitrary and axially symmetric profile by a polishing process

Abstract In this study, a machining strategy for a polishing process to remove an arbitrary and axially symmetric profile is proposed. The strategy is to plan the tool motion so that a desired profile can be accurately machined. From the volume removing analysis of a polishing process, it is suggested that the dwelling time of the tool at a position should be a linear function of the product of the depth to be removed by its corresponding radius. By using this strategy, three types of errors may be induced: the machining time–distribution error, the ripple error and the resolution error. It is shown that these errors are related to the profile, the tool step, the volume removing rate and the size of the machining zone. The qualitative and quantitative properties of these errors are analyzed. This analysis indicates that a dominant factor in deciding these errors is the tool step size. By increasing this size, both the machining time–distribution error and the resolution error are reduced but the ripple error is enhanced. A tactic is proposed to solve the conflict in choosing the tool step. The experimental study conforms that the proposed strategy can accurately remove an arbitrary profile and the error analysis is reasonable.