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Supervisor's Foreword; Parts of this thesis have been published in the following journal articles/chapters from various books:D.W.K. Neo, A.S. Kumar and M. Rahman, 'CAx technologies for hybrid fast tool/slow slide servo diamond turning of freeform surface', Proceedings of the Institution of Mechanical Engineers, Part B, J. Engineering Manufacture (2016) 230(8): 1465-1479D.W.K. Neo, A.S. Kumar and M. Rahman, 'Automated Guilloche machining technique for the fabrication of polygonal Fresnel lens array', Precision Enginee; Acknowledgements; Contents; Acronyms; Symbols; Summary; 1 Introduction
1.1 Hybrid Freeform Surfaces1.2 Ultraprecision Machining of Hybrid Freeform Surfaces; 1.3 Main Objectives of This Dissertation; 1.4 Organization of This Dissertation; References; 2 Literature Review; 2.1 Multiple-Axis Ultraprecision Diamond Machining Techniques; 2.1.1 Fast Tool Servo (FTS); 2.1.2 Slow Slide Servo (SSS); 2.1.3 Other Multiple-Axis Ultraprecision Machining Techniques; 2.2 State-of-Art CAD/CAM/CAE Technologies; 2.2.1 CAD/CAM Technology for Surface Generation; 2.2.2 Surface Accuracy and Error Compensation Approaches; 2.3 Concluding Remarks; References
3 Initial Development of CAD/CAM Technologies3.1 CAD/CAM for Multiple-Axis Ultraprecision Machining Processes; 3.1.1 Non-uniform Rational B-Spline Freeform Surfaces; 3.1.2 CAD/CAM Interpolator for FTS/SSS Diamond Turning; 3.2 API Methodology for CAD/CAM Software Development; 3.2.1 Experimental Validation; 3.3 Concluding Remarks; References; 4 Development of Hybrid FTS/SSS Diamond Turning; 4.1 Principle of Layered Tool Trajectory; 4.2 Layered Tool Trajectory Control; 4.3 Experimental Validations; 4.4 Concluding Remarks; References; 5 Novel Surface Generation of Complex Hybrid Freeform Surfaces
6.2.2 Cutting Experiments and Results6.3 Concluding Remarks; References; 7 Integration and Implementation; 7.1 Integrated CAD/CAM System; 7.1.1 Integrated Sub-system for AGMT Process; 7.1.2 Integrated Sub-system for Diamond Turning Process; 7.1.3 Optimization of Tool Geometry; 7.1.4 Geometrical Splitting of Hybrid Freeform Surface; 7.2 Case Study 1: Hexagonal Fresnel Lens Array Using AGMT Process; 7.2.1 Experimental Validations; 7.2.1.1 Critical Machining Parameters for AGMT Process; 7.2.1.2 Cutting Experiments and Results; 7.3 Case Study 2: Multiple-Compound Eye Surface Design-B
1.1 Hybrid Freeform Surfaces1.2 Ultraprecision Machining of Hybrid Freeform Surfaces; 1.3 Main Objectives of This Dissertation; 1.4 Organization of This Dissertation; References; 2 Literature Review; 2.1 Multiple-Axis Ultraprecision Diamond Machining Techniques; 2.1.1 Fast Tool Servo (FTS); 2.1.2 Slow Slide Servo (SSS); 2.1.3 Other Multiple-Axis Ultraprecision Machining Techniques; 2.2 State-of-Art CAD/CAM/CAE Technologies; 2.2.1 CAD/CAM Technology for Surface Generation; 2.2.2 Surface Accuracy and Error Compensation Approaches; 2.3 Concluding Remarks; References
3 Initial Development of CAD/CAM Technologies3.1 CAD/CAM for Multiple-Axis Ultraprecision Machining Processes; 3.1.1 Non-uniform Rational B-Spline Freeform Surfaces; 3.1.2 CAD/CAM Interpolator for FTS/SSS Diamond Turning; 3.2 API Methodology for CAD/CAM Software Development; 3.2.1 Experimental Validation; 3.3 Concluding Remarks; References; 4 Development of Hybrid FTS/SSS Diamond Turning; 4.1 Principle of Layered Tool Trajectory; 4.2 Layered Tool Trajectory Control; 4.3 Experimental Validations; 4.4 Concluding Remarks; References; 5 Novel Surface Generation of Complex Hybrid Freeform Surfaces
6.2.2 Cutting Experiments and Results6.3 Concluding Remarks; References; 7 Integration and Implementation; 7.1 Integrated CAD/CAM System; 7.1.1 Integrated Sub-system for AGMT Process; 7.1.2 Integrated Sub-system for Diamond Turning Process; 7.1.3 Optimization of Tool Geometry; 7.1.4 Geometrical Splitting of Hybrid Freeform Surface; 7.2 Case Study 1: Hexagonal Fresnel Lens Array Using AGMT Process; 7.2.1 Experimental Validations; 7.2.1.1 Critical Machining Parameters for AGMT Process; 7.2.1.2 Cutting Experiments and Results; 7.3 Case Study 2: Multiple-Compound Eye Surface Design-B