The conventional approach to establish optimal processing conditions in ultraprecision diamond turning is empirical in nature. The achievement of a super mirror finish and submicrometre form accuracy in many current industrial applications still depends much on the experience and skills of the machine operators through trial cutting tests when new materials or new machine tools are used. In this paper, a virtual machining and inspection system (VMIS) is presented for ultra-precision diamond turning. The development of the VMIS aims at creating a virtual manufacturing environment for the optimization of process parameters and evaluating the quality of machined surface through various modelbased simulation modules. The VMIS is validated through a series of practical cutting tests conducted on a two-axis computer numerical control ultra-precision turning machine. The experimental results agree well with the simulated data.
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