1. By Nathan Buescher November 7, 2003
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