Manufacturing and measurement of freeform optics

Thermal issues in machine tools

Ultra-precision grinding is primarily used to generate high quality and functional parts usually made from hard and difficult to machine materials. The objective of ultra-precision grinding is to generate parts with high surface finish, high form accuracy and surface integrity for the electronic and optical industries as well as for astronomical applications. This keynote paper introduces general aspects of ultra-precision grinding techniques and point out the essential features of ultra-precision grinding. In particular, the keynote paper reviews the state-of-the-art regarding applied grinding tools, ultra-precision machine tools and grinding processes. Finally, selected examples of advanced ultra-precision grinding processes are presented.

Ultra-precision grinding

Molecular dynamics (MD) simulation has enhanced our understanding about ductile-regime machining of brittle materials such as silicon and germanium. In particular, MD simulation has helped understand the occurrence of brittle–ductile transition due to the high-pressure phase transformation (HPPT), which induces Herzfeld–Mott transition. In this paper, relevant MD simulation studies in conjunction with experimental studies are reviewed with a focus on (i) the importance of machining variables: undeformed chip thickness, feed rate, depth of cut, geometry of the cutting tool in influencing the state of the deviatoric stresses to cause HPPT in silicon, (ii) the influence of material properties: role of fracture toughness and hardness, crystal structure and anisotropy of the material, and (iii) phenomenological understanding of the wear of diamond cutting tools, which are all non-trivial for cost-effective manufacturing of silicon. The ongoing developmental work on potential energy functions is reviewed to identify opportunities for overcoming the current limitations of MD simulations. Potential research areas relating to how MD simulation might help improve existing manufacturing technologies are identified which may be of particular interest to early stage researchers.

/pdf/diamond-machining-of-silicon-a-review-of-advances-in-h5mvksdo94.pdf

Diamond machining of silicon: A review of advances in molecular dynamics simulation

The core performance elements of global navigation satellite system include availability, continuity, integrity and accuracy, all of which are particularly important for the developing BeiDou global navigation satellite system (BDS-3). This paper describes the basic performance of BDS-3 and suggests some methods to improve the positioning, navigation and timing (PNT) service. The precision of the BDS-3 post-processing orbit can reach centimeter level, the average satellite clock offset uncertainty of 18 medium circular orbit satellites is 1.55 ns and the average signal-in-space ranging error is approximately 0.474 m. The future possible improvements for the BeiDou navigation system are also discussed. It is suggested to increase the orbital inclination of the inclined geostationary orbit (IGSO) satellites to improve the PNT service in the Arctic region. The IGSO satellite can perform part of the geostationary orbit (GEO) satellite’s functions to solve the southern occlusion problem of the GEO satellite service in the northern hemisphere (namely the “south wall effect”). The space-borne inertial navigation system could be used to realize continuous orbit determination during satellite maneuver. In addition, high-accuracy space-borne hydrogen clock or cesium clock can be used to maintain the time system in the autonomous navigation mode, and stability of spatial datum. Furthermore, the ionospheric delay correction model of BDS-3 for all signals should be unified to avoid user confusion and improve positioning accuracy. Finally, to overcome the vulnerability of satellite navigation system, the comprehensive and resilient PNT infrastructures are proposed for the future seamless PNT services.

/pdf/basic-performance-and-future-developments-of-beidou-global-18ysrcaj1o.pdf

Basic performance and future developments of BeiDou global navigation satellite system

The Comite international des poids et mesures (CIPM) has projected a major revision of the International System of Units (SI) in which all of the base units will be defined by fixing the values of fundamental constants of nature. In preparation for this we have carried out a new, low-uncertainty determination of the Boltzmann constant, kB, in terms of which the SI unit of temperature, the kelvin, can be re-defined. We have evaluated kB from exceptionally accurate measurements of the speed of sound in argon gas which can be related directly to the mean molecular kinetic energy, . Our new estimate is kB = 1.380 651 56 (98) × 10−23 J K−1 with a relative standard uncertainty uR = 0.71 × 10−6.

https://iopscience.iop.org/article/10.1088/0026-1394/50/4/354/pdf

A low-uncertainty measurement of the Boltzmann constant

Precision engineering for astronomy and gravity science

This paper provides a perspective on the development of ultra-precision technologies: What drove their evolution and what do they now promise for the future as we face the consequences of consumption of the Earth's finite resources? Improved application of measurement is introduced as a major enabler of mass production, and its resultant impact on wealth generation is considered. This paper identifies the ambitions of the defence, automotive and microelectronics sectors as important drivers of improved manufacturing accuracy capability and ever smaller feature creation. It then describes how science fields such as astronomy have presented significant precision engineering challenges, illustrating how these fields of science have achieved unprecedented levels of accuracy, sensitivity and sheer scale. Notwithstanding their importance to science understanding, many science-driven ultra-precision technologies became key enablers for wealth generation and other well-being issues. Specific ultra-precision machine tools important to major astronomy programmes are discussed, as well as the way in which subsequently evolved machine tools made at the beginning of the twenty-first century, now provide much wider benefits.

https://royalsocietypublishing.org/doi/pdf/10.1098/rsta.2011.0638

Paul Morantz

Papers

A low-uncertainty measurement of the Boltzmann constant

Precision engineering for astronomy and gravity science

Ultra-precision: enabling our future

Grinding metre scale mirror segments for the E-ELT ground based telescope

Current trends and future of sequential micro-machining processes on a single machine tool