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The goal of this book is to familiarize professionals, researchers, and students with the basics of the Diamond Turn Machining Technology and the various issues involved. The book provides a comprehensive knowledge about various aspects of the technology including the background, components of the machine, mechanism of material removal, application areas, relevant metrology, and advances taking place in this domain. Solved and unsolved examples are provided in each of the areas which will help the readers to practice and get familiarized with that particular area of the Diamond Turn Machining process.
An Engineering Research Series title. One of the remarkable achievements of modern manufacturing techniques is the ability to achieve nano-metre surface finishes. Ultraprecision machining based on single-point diamond turning (SPDT) is a very important technique in the manufacture of high-precision components where surface finish is critical. Complex optical surfaces, for example, can be produced without the need for post-machining polishing. This book focuses on the aspect of modelling nano-surface generation in ultra precision SPDT. Potential industrial applications in the prediction of surface quality, the process optimization, and precision mould manufacturing are also studies. The essential differences between single-point diamond turning and conventional machining are described. The history and technology of single-point diamond turning are presented and single chapters emphasize the related metrology and cutting mechanics. Important aspects of surface generation are also discussed. Features of the text are the sound approach, systematic mathematical modelling, and computer-aided simulation of surface generation in the development of surfaces exhibiting nano-surface qualities. TOPICS COVERED INCLUDE: Fundamentals of ultra-precision diamond turning technology Cutting mechanics and analysis of microcutting force variation Mechanisms of surface generation Characterization and modelling of nano-surface generation Computer-aided simulation of nano-surface generation Diamond turning of aspheric optics. Based upon the extensive experience of the authors Surface Generation in Ultra-precision Diamond Turning: Modelling and Practices will be of interest to engineers, scientists, and postgraduate students.
This thesis focuses on producing hybrid freeform surfaces using an advanced diamond-turning process, understanding the generation of surface accuracies (form errors) and how the choice of cutting strategies affects these, as well as simplifying the complications of generating cutting paths for such freeform surfaces. The breakthroughs behind this thesis are the development of novel, multiple-axis, diamond turning techniques to overcome the limitations of conventional diamond turning processes, an analytical model to optimize the generation of ultraprecise freeform surfaces, and an add-on tool path processor for CAD/CAM software solutions. It appeals to researchers and scholars with a strong machining background who are interested in the field of manufacturing ultraprecise freeform surfaces or in the field of optimizing ultraprecision machining processes.
This book presents an in-depth study and elucidation on the mechanisms of the micro-cutting process, with particular emphasis and a novel viewpoint on materials characterization and its influences on ultra-precision machining. Ultra-precision single point diamond turning is a key technology in the manufacture of mechanical, optical and opto-electronics components with a surface roughness of a few nanometers and form accuracy in the sub-micrometric range. In the context of subtractive manufacturing, ultra-precision diamond turning is based on the pillars of materials science, machine tools, modeling and simulation technologies, etc., making the study of such machining processes intrinsically interdisciplinary. However, in contrast to the substantial advances that have been achieved in machine design, laser metrology and control systems, relatively little research has been conducted on the material behavior and its effects on surface finish, such as the material anisotropy of crystalline materials. The feature of the significantly reduced depth of cut on the order of a few micrometers or less, which is much smaller than the average grain size of work-piece materials, unavoidably means that conventional metal cutting theories can only be of limited value in the investigation of the mechanisms at work in micro-cutting processes in ultra-precision diamond turning.
This paper will be of special interest to those wanting to find out about diamond turning. The history and development of diamond turning is reviewed including personal insights from being with the technology from its earliest stages. Applications which have demonstrated the unique capabilities and accuracies for difficult geometries are given. The state-of-the-art review includes accuracies, sizes, and weights. Developing diamond turning production capabilities and the impact of the DOD Manufacturing Technology Transfer program is summarized. Rules of thumb and insights into when diamond turning or other optical fabrication techniques should be used are also given. Future laser resonators may depend on diamond turning for axicon, reflaxicon, and waxicons. DARPA sponsored Large Optics Diamond Turning Machine (LODTM) is summarized. LODTM will have a capacity for 1.6 m diameter parts to be machined to 2.0 u (500 A) rms figure accuracy.
Hybrid Machining: Theory, Methods, and Case Studies covers the scientific fundamentals, techniques, applications and real-world descriptions of emerging hybrid machining technology. This field is advancing rapidly in industrial and academic contexts, creating a great need for the fundamental and technical guidance that this book provides. The book includes discussions of basic concepts, process design principles, standard hybrid machining processes, multi-scale modeling approaches, design, on-machine metrology and work handling systems. Readers interested in manufacturing systems, product design or machining technology will find this one-stop guide to hybrid machining the ideal reference. Includes tables of recommended processing parameters for key engineering materials/products for each hybrid machining process Provides case studies covering real industrial applications Explains how to use multiscale modeling for hybrid machining
Abstract: The ultraprecision Single Point Diamond Turning (SPDT) technology has been developed for over 40 years and has been successfully applied to numerous fields. At present, the ultraprecision single point diamond turning technology already expanded to Single Point Diamond Machining (SPDM) technology, which includes several related processes in addition to the more conventional single point diamond turning. The other related processes are Fast Tool Servo (FTS), Slow Tool Servo (STS), broaching, and fly cutting. Though this technology has many notable merits, for example it can achieve micro meter or even sub micron form accuracy and nano meter surface roughness, there still has some drawbacks. One of the objectives of this research is to investigate one of these drawbacks, the diffraction and scattering of the ultraprecision single point diamond machined surfaces. Another objective is to extend the application of the SPDM by developing new design and new machining processes for freeform micro devices used in optical, mechanical, electronic, and biomedical fields. The mechanism and model of the ultraprecision single point diamond turning and micro cutting were first reviewed and discussed. The related subjects to the SPDT and micro cutting were also involved. The optical effects of diamond machined surfaces were studied. The diffraction and scattering generated from the diamond machined surfaces was analytically and experimentally studied. The influences from machining parameters, such as tool mark spacing, feedrate, spindle speed, tool radius, tool condition and different diamond machining process were considered. An empirical relationship between the machining conditions and the first order diffraction from the diamond machined surfaces was setup. This model can be used to select optimal machining conditions for diamond machining process. The design, machining and testing of microlens arrays by using SPDM process were introduced. Two microlens array examples were given. One is a 5 by 5 matrix arranged concave microlens array on flat brass substrate. The other one is a circular arranged 3D microlens array, which has 341 plano-convex micro lenslets, on a thin spherical PMMA substrate. Using the fabricated 3D microlens array, a 3D micro projection system was developed. The formed micro pattern dimension was 340 um by 460 um, giving an overall projection ratio of 34:1. It has been demonstrated that a low cost and simple manufacturing process for true 3D micro scale structures on non-planar substrates based on microlenses can be realized. Last but not least, an affordable polymer SAR micromixer was developed based on a high accuracy, low cost, and flexible micro machining process. Specifically both the mixing performance and the fabrication process were carefully studied. An improved design of the SAR micromixer was also given, the mixing efficiency of the two designs were 0.11 and 0.065 respectively.