Research of Surface Generation Mechanisms in Single-Point Diamond Turning

2007 ◽  
Vol 364-366 ◽  
pp. 1296-1301
Author(s):  
Chi Fai Cheung ◽  
Wing Bun Lee ◽  
Suet To ◽  
Ling Bao Kong
Keyword(s):  
Surface Roughness ◽  
High Precision ◽  
Single Point ◽  
Diamond Turning ◽  
Surface Generation ◽  
Optical Surfaces ◽  
Surface Finishes ◽  
Generation Mechanisms

One of the remarkable achievements of nanotechnology is the ability to achieve nanometric surface finishes in single-point diamond turning of high-precision components for complex optical surfaces. A better understanding of the surface generation mechanisms is of prime importance for the development for the prediction of the surface roughness. This paper presents a study of mechanisms of nano-surface generation in single-point diamond turning of various types of materials.

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.

scholarly journals Machinability and Surface Generation of Pd40Ni10Cu30P20 Bulk Metallic Glass in Single-Point Diamond Turning

Micromachines ◽  
2019 ◽  
Vol 11 (1) ◽  
pp. 4 ◽  
Author(s):  
Jie Xiong ◽  
Hao Wang ◽  
Guoqing Zhang ◽  
Yanbing Chen ◽  
Jiang Ma ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metallic Glass ◽  
Bulk Metallic Glass ◽  
Tool Path ◽  
Single Point ◽  
Chip Morphology ◽  
Diamond Turning ◽  
Surface Generation ◽  
Workpiece Material ◽  
Machined Surface

Pd40Ni10Cu30P20 bulk metallic glass (BMG) is widely used in industrial fields due to its excellent oxidation resistance, corrosion resistance, and thermal stability. However, the lack of research on the machinability and cutting performance of BMG using single-point diamond turning (SPDT) limits its application for engineering manufacturing. In the present research, a series of turning experiments were carried out under different cutting parameters, and the machinability reflected by the quality of machined surface, chip morphology, and tool wear were analyzed. Based on the oxidation phenomenon of the machined surface, a molecular dynamics (MD) simulation was conducted to study the mechanism and suppression of the machined surface oxidation during the cutting. The results show that: (1) The Pd-based BMG had good machinability, where the machined surface roughness could go down to 3 nm; (2) irregular micro/nanostructures were found along the tool path on the outer circular region of the machined surface, which greatly affected the surface roughness; and (3) the cutting heat softened the workpiece material and flattened the tool marks under surface tension, which improved the surface quality. This research provides important theoretical and technical support for the application of BMG in optical mold manufacturing.

Analysis of the Swelling Effect in Single-Point Diamond Turning

2011 ◽  
Vol 314-316 ◽  
pp. 984-987
Author(s):  
Qing Liang Zhao ◽  
Jun Yun Chen ◽  
Jian Luo
Keyword(s):  
Surface Roughness ◽  
Material Property ◽  
Single Point ◽  
Diamond Turning ◽  
Surface Generation ◽  
Ductile Material ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Tool Mark ◽  
Material Swelling

The swelling effect is an important factor to affect surface generation in SPDT. Face cutting experiments are conducted for copper, aluminum alloy and electroless nickel phosphorus to analyze the swelling effect including the relationship between it and cutting parameters as well as effect of material property. How the material swelling affects surface roughness is also studied in this paper. The results indicate that the swelling effect is influenced by spindle speed and material property more remarkably when compared to feed rate and depth of cut. In addition, a softer and more ductile material will lead to a stronger material recovery, a lower swelling proportion, a lower tool mark height and a smoother machined surface. The result reveals that the swelling effect must be considered when predicting surface roughness in SPDT

Surface Characterization in Diamond Turning of Highly Anisotropy Brittle Crystals: A Multi-Spectrum Analysis Approach

2006 ◽  
Vol 532-533 ◽  
pp. 989-992
Author(s):  
Chi Fai Cheung ◽  
Wing Bun Lee ◽  
Suet To
Keyword(s):  
Surface Roughness ◽  
Power Spectrum ◽  
Spectrum Analysis ◽  
Surface Characterization ◽  
Single Point ◽  
Diamond Turning ◽  
Surface Generation ◽  
Factors Affecting ◽  
Important Means ◽  
Brittle Crystals

This paper presents a multi-spectrum analysis method for the characterization of the surface generation in single-point turning of brittle single crystals. The features on the diamond turned surfaces were extracted and analysed by the power spectrum analysis of the surface roughness profiles measured at a number radial sections of the workpiece. By the analysis of the variation of the spectral patterns in the multi-spectrum plots, the surface roughness and materials effect on surface generation are found to be strongly related to the power spectrum. This provides an important means to explain quantitatively the effect of factors affecting the surface generation in diamond turning brittle crystals.

Effect of Coolant Type on Surface Roughness and RSM Modelling in Single-Point Diamond Turning of RSA443 Optical Aluminum

2020 ◽  
Vol 305 ◽  
pp. 117-121 ◽  
Author(s):  
Zvikomborero Hweju ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Single Point ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Relative Difference ◽  
Diamond Turning ◽  
Percentage Error ◽  
Depth Of Cut ◽  
Surface Finishes ◽  
Roughness Prediction

This paper is a presentation of a comparative study of the effect of water and kerosene coolants on surface finish during ultra-high precision diamond turning (UHPDT) of Rapidly Solidified Aluminium alloy (RSA 443). The percentage relative difference between the coolants’ surface roughness values is denoted by the ΔRa parameter. The accuracy of the Response Surface Method (RSM) in predicting surface roughness of water and kerosene-based results is investigated in this paper. The cutting parameters used in the investigation are cutting speed, feed rate and depth of cut. The Taguchi method was used to design the experiment since it provides relatively fewer experimental runs when compared to classical experimental design methods. Mean Absolute Percentage Error (MAPE) values are used to compare RSM’s surface roughness prediction accuracy on both water and kerosene-based results. It is observed that the surface roughness profiles for either coolant are similar, and the use of water coolant yields smoother surface finishes when compared to the use of kerosene. It is also observed that RSM displays better accuracy in predicting water-based surface roughness.

Study on the control of surface roughness in single point diamond turning

2012 ◽  
Author(s):  
Honghuai Xu ◽  
Xiangchao Zhang ◽  
Min Xu ◽  
Xufeng Li
Keyword(s):  
Surface Roughness ◽  
Single Point ◽  
Diamond Turning
Sign in / Sign up

Export Citation Format

Share Document