Diamond turning

About: Diamond turning is a research topic. Over the lifetime, 1849 publications have been published within this topic receiving 24301 citations.

Review of vibration-assisted machining

Abstract: Vibration-assisted machining (VAM) combines precision machining with small-amplitude tool vibration to improve the fabrication process. It has been applied to a number of processes from turning to drilling to grinding [9] , [36] . The emphasis on this literature review is the turning process where VAM has been applied to difficult applications such as diamond turning of ferrous and brittle materials, creating microstructures with complex geometries for products like molds and optical elements, or economically producing precision macro-scale components in hard alloys such as Inconel or titanium. This review paper presents the basic kinematic relationships for 1D (linear vibratory tool path) and 2D VAM (circular/elliptical tool path). Typical hardware systems used to achieve these vibratory motions are described. The periodic separation between the tool rake face and uncut material, characteristic of VAM, is related to observed reductions in machining forces and chip thickness, with distinct explanations offered for 1D and 2D modes. The reduced tool forces in turn are related to improvements in surface finish and extended tool life. Additional consideration is given to the intermittent cutting mechanism and how it reduces the effect of thermo-chemical mechanisms believed responsible for rapid wear of diamond tools when machining ferrous materials. The ability of VAM to machine brittle materials in the ductile regime at increased depth of cut is also described.

Ductile‐Regime Machining of Germanium and Silicon

Abstract: Precision machining of germanium and silicon was studied using single-point diamond turning. Special attention was directed to the so-called ductile regime wherein optical quality surface finishes can be machined directly on brittle materials. A novel interrupted-cutting test and a new model of the machining process were used to measure a critical-depth parameter experimentally. This parameter governs the transition from plastic flow to fracture along the tool nose. The critical-depth parameter can be used to provide physical insight into the effect of various machining parameters such as tool rake angle or tool clearnace angle. Because of a complex interplay between tool geometry, machining parameters, and material response, a large fraction of material removal occurs by fracture even when ductile-regime conditions are achieved.

Chemical aspects of tool wear in single point diamond turning

Abstract: A hypothesis is proposed that ascribes chemical wear of diamond tools to the presence of unpaired d electrons in the sample being machined. This hypothesis is used to explain a range of results for metals, alloys, and other materials including “electroless” nickel. The hypothesis is further tested by experiments presented here on the machining of a range of high purity elements. The implications for diamond turnability of other materials are discussed.

Precision nano-fabrication and evaluation of a large area sinusoidal grid surface for a surface encoder

Abstract: This paper describes the fabrication of a large area sinusoidal grid surface, which is used as the measurement reference of a surface encoder for multi-axis position measurement. The profile of the grid surface is a superposition of sinusoidal waves in the X-direction and the Y-direction with spatial wavelengths of 100 μm and amplitudes of 100 nm. Diamond turning with a fast tool servo (FTS) was chosen as the fabrication method. The constructed FTS, which employs a piezoelectric tube actuator (PZT) to actuate the diamond tool and a capacitance probe as the feedback sensor, was confirmed to have a bandwidth of approximately 2.5 kHz and a tool displacement accuracy of several nanometers in the closed-loop mode. Experiments of fabricating the sinusoidal grid surface were performed on a commercially available precision diamond turning machine. An aluminum alloy workpiece was vacuum chucked on the spindle and the FTS was mounted on the X-slide. Efforts were made to position the tool tip to the center of the spindle (center-alignment) since it was verified that the center-alignment is important for the fabrication accuracy of the sinusoidal grid surface. An evaluation technique based on the two-dimensional (2D) discrete Fourier transform (DFT) of interference microscope images was also developed to evaluate the fabricated grid surface effectively. The fabrication result of a grid surface over an area of ∅ 150 mm has indicated the effectiveness of the fabrication system.

Ductile-regime machining model for diamond turning of brittle materials

Abstract: A new machining model has been developed for single point diamond turning of brittle materials. Experiments using the interrupted cutting method allow model parameters to be determined that provide a quantitative method for determining the machinability of a material with respect to the rake angle, tool nose radius and machining environment. The model uses two parameters, the critical depth of cut and the subsurface damage depth, to characterize the ductile-regime material removal process. Also included in the model is a parameter used to set a process limit defined as the maximum feed rate. Machining experiments have verified the model, and allow for determination of optimum machining conditions.