Effect of Cutting Parameters on Materials Swelling of Machined Surfaces in Single-point Diamond Turning(Ultra-precision machining)

2005 ◽  
Vol 2005.3 (0) ◽  
pp. 1051-1056
Author(s):  
M.C. KONG ◽  
W.B. LEE ◽  
C.F. CHEUNG ◽  
S. TO
Keyword(s):  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Precision Machining ◽  
Ultra Precision ◽  
Machined Surfaces

Experiment and Discussion on Ultrasonic Vibration-Assisted Single Point Diamond Turning of Die Steels

2012 ◽  
Vol 497 ◽  
pp. 1-5
Author(s):  
Xiao Dan Xie ◽  
Yong Li ◽  
Cam Vinh Duong ◽  
Ahmed Al-Zahrani
Keyword(s):  
Tool Wear ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Process ◽  
Die Steels ◽  
Ultra Precision ◽  
Promising Solution ◽  
Vibration Parameters

Traditionally, single point diamond turning (SPDT) can not process ferreous metals because of acute tool wear. Ultrasonic vibration-assisted cutting(UVC) provides a promising solution for the problem. In this paper, for the aim of directly obtaining mirror surface on die steels, UVC method was used combining with SPDT process. Experiments were carried out on an ultra precision turning machine, cutting parameters and vibration parameters were well-chosen, and two kind of feed rates, two kinds of prevailing die steels were experimented. Mirror surfaces were successfully achieved on face turning, with the best roughness of Ra16.6nm. And the surface roughness, surface texture and tool wear in machining process were discussed.

VSPDT: An Optimizer for Single Point Diamond Turning

2007 ◽  
Vol 339 ◽  
pp. 447-452
Author(s):  
Jian Guang Li ◽  
Wing Bun Lee ◽  
Chi Fai Cheung ◽  
Sandy To ◽  
J.J. Du ◽  
...  
Keyword(s):  
New Product Development ◽  
Functional Performance ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Virtual Manufacturing ◽  
Form Error ◽  
Ultra Precision ◽  
Virtual Workpiece ◽  
Optimal Cutting Parameters

Virtual manufacturing (VM), which primarily aimed at reducing the lead times to market and costs associated with new product development, offers various test-beds for the time-consuming and expensive physical experimentation. Since surface roughness and form accuracy play essential roles in the functional performance of the products machined with ultra-precision machining technology. An optimizer, VSPDT (virtual single point diamond turning) system was developed for the purpose of form error compensation and optimal cutting parameters selection. In this paper, the keys issues for developing VSPDT using virtual manufacturing technology were highlighted such as framework of system, virtual workpiece, virtual machining and inspection, etc. At the end of the paper, A VSPDT was developed and applied to predict and compensate the form error, select optimal cutting parameters by using a 2-axis CNC ultra-precision turning machine.

Manufacturing Process of Terahertz Radar Reflector Based on Ultra-Precision Machining Technology

2015 ◽  
Vol 713-715 ◽  
pp. 633-636
Author(s):  
Di Li ◽  
Song Bao Luo ◽  
Jian Ming Zhang ◽  
Chang Yu Xu ◽  
Chang Tao Pang
Keyword(s):  
Single Point ◽  
Cutting Tools ◽  
Diamond Turning ◽  
Precision Machining ◽  
Diamond Cutting Tools ◽  
Single Crystal Diamond ◽  
Aluminum Sample ◽  
Ultra Precision ◽  
The Cost ◽  
Better Than

This paper presents a technique for processing Terahertz radar reflector by SPDT (Single Point Diamond Turning) based on LODTM (Large Optics Diamond Turning Machine). This technique applies single crystal diamond cutting tools for ultra-precision machining, and thus could obtain high-precision optical mirror, which could be used as the Terahertz radar reflectors. An experiment for aluminum sample had been done to demonstrate the availability of the technique, and a pair of Terahertz radar reflectors were obtained. The precision of the reflectors, detected through precision coordinate measuring technology, was better than the designed requirement. The experiment results showed that Terahertz radar reflectors generated by deterministic ultra-precision machining technique based on LODTM would have advantages in figure accuracy and roughness and so on, which could be helpful to improve the precision and low the cost of Terahertz radar system.

Form Accuracy of Optical Mould Inserts Made from Rapidly Solidified Aluminium Alloys

2015 ◽  
Vol 828-829 ◽  
pp. 62-68
Author(s):  
Khaled Abou-El-Hossein
Keyword(s):  
High Precision ◽  
Surface Finish ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Parameters ◽  
Optical Surface ◽  
Form Accuracy ◽  
Optical Surfaces ◽  
Rapidly Solidified

Plastic optical components and lenses produced in mass quantities are usually manufactured using high-precision plastic injection technology. For that, high-precision plastic moulds with aluminium optical inserts made with extremely high dimension accuracy and high optical surface quality are used. Ultra-high precision single-point diamond turning have been successfully used in shaping optical mould inserts from various aluminium grades such as traditional 6061. However, extreme care should be taking when selecting machining parameters in order to produce optically valid surfaces before premature tool wear takes place especially when the machined optical materials has inadequate machining database. The current experimental study looks at the effect of cutting conditions on optical surfaces made from aluminium. The study embarks on helping establish some diamond machining database that helps engineers select the most favourable cutting parameters. The papers reports on the accuracy and surface finish quality received on an optical surface made on mould inserts from a newly developed aluminium alloy. Rapidly solidified aluminium (RSA) grades have been developed recently to address the various problems encountered when being cut by single-point diamond turning operation. The material is characterised by its extremely fine grained microstructure which helps extend the tool life and produce optical surfaces with nanometric surface finish. It is found the RSA grades can be successfully used to replace traditional optical aluminium grades when making optical surfaces. Surface finishes of as low as 10 nanometres and form accuracy of less than one micron can be achieved on RSA.

Microfluidic Manifolds with High Dynamic Range in Structural Dimensions Replicated in Thermoplastic Materials

2009 ◽  
Vol 1191 ◽  
Author(s):  
Holger Becker ◽  
Erik Beckert ◽  
Claudia Gärtner
Keyword(s):  
Structural Dynamics ◽  
Manufacturing Process ◽  
Dynamic Range ◽  
Single Point ◽  
Mold Insert ◽  
High Dynamic Range ◽  
Diamond Turning ◽  
Precision Machining ◽  
Wetting Properties ◽  
High Dynamic

AbstractIn this paper, we present the manufacturing process of a polymer microfluidic device which is currently being used to investigate wetting properties of nanostructured microchannels replicated in hydrophobic thermoplastic materials like cyclo-olefin co-polymer (COC), polypropylene (PP) or polymethylmetacrylate (PMMA). These devices feature large structural dynamics (feature sizes between 200 μm and 200 nm). The mold insert necessary was fabricated using a combination of precision machining with single-point diamond turning (SPDT).

Optical Effects of Surface Finish by Ultraprecision Single Point Diamond Machining

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lei Li ◽  
Stuart A. Collins ◽  
Allen Y. Yi
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Diamond Turning ◽  
Optical Diffraction ◽  
Machining Process ◽  
Machined Surface ◽  
Tool Marks ◽  
Tool Mark ◽  
Machined Surface Quality ◽  
Machined Surfaces

The single point diamond turning process has been used extensively for direct optical surface fabrication. However, the diamond machined surfaces have characteristic periodic tool marks, which contribute to reduced optical performance such as scattering and distortion. In this paper, studies of the characteristics of diamond machined surface and scattering from the diamond machined surfaces are presented. Four different parameters, the first order optical diffraction, the zero order reflection, the surface roughness, and the residual tool mark depth, are used as indicators for the machined surface quality. Four sets of tests are presented showing the relationship between machined surface quality and machining conditions such as spindle speed, feedrate, and machining process. Finally, an empirical model is given based on the measurements.

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