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

Study, analysis, and characterization of ultra-precision diamond tools for single-point diamond turning

2020 ◽  
pp. 251659842096533
Author(s):  
RamaGopal V. Sarepaka ◽  
Sivasakthi Balan ◽  
Somaiah Doodala ◽  
Rakesh Singh Panwar ◽  
D. Rajendra Kotaria
Keyword(s):  
Surface Roughness ◽  
Diamond Tool ◽  
Single Point ◽  
Quality Parameters ◽  
Diamond Turning ◽  
Radius Of Curvature ◽  
Tool Selection ◽  
Diamond Tools ◽  
Surface Irregularities ◽  
Ultra Precision

In multiple applications of advanced instrumentation, single-point diamond turning (SPDT) is a popular and effective process to generate novel surfaces with nanometric surface roughness and sub-micron surface irregularities, albeit at a high cost. In SPDT, precision diamond tooling contributes significantly to the process cost escalation. Hence, for SPDT, it is vital to have an optimal precision diamond tool deployment. In this article, details of comprehensive precision diamond tool selection and tool characterization are discussed. Three makes of selected ultra-precision diamond (UPD) tools and standard diamond tools (of a global make), designated as CFT, are considered for this study. In this tool bench-marking exercise, the fabrication of Cu–Be alloy predesigned precision components (PDPCs) of a critical geometry is selected. UPD and CFT tools are deployed to fabricate (under similar machining-metrology conditions) the PDPCs. These diamond tools are evaluated in terms of the quality parameters (variation in radius of curvature, form error, and surface roughness) of the workpieces. Further, to explore the progressive wear of these tools, multiple machining cycles are conducted on these workpieces, and their quality parameters are analyzed. Thus, the precision diamond tools of three makes are benchmarked against the CFT tool. Based on the final outcome of this analysis, suitable recommendations are provided to precision diamond tool manufacturers to improve their product in terms of performance and optimized costs to meet the ever-growing tooling demands of the SPDT community.

Freeform machining of ophthalmic toric lens mould using fast tool servo-assisted ultra-precision diamond turning process

2020 ◽  
pp. 251659842093974
Author(s):  
Ishan Anand Singh ◽  
Gopi Krishna S. ◽  
T. Narendra Reddy ◽  
Prakash Vinod
Keyword(s):  
Surface Roughness ◽  
Single Point ◽  
Measurement Data ◽  
Surface Profile ◽  
Diamond Turning ◽  
Fast Tool Servo ◽  
Toric Surface ◽  
Machined Surface ◽  
Ultra Precision ◽  
A Minor

This research aims to establish a methodology for machining of toric lenses, using fast tool servo-assisted single point diamond turning and to assess the generated surface for its characteristics. Using the established mathematical model, toric surface is explained to understand the geometry and to generate the parameters required for fast tool servo machining. A toric surface with a major diameter of 18.93 mm and a minor diameter of 15.12 mm has been cut on the intelligent ultra-precision turning machine (iUPTM). The surface profile and surface roughness were measured. After analysing the measurement data of the machined surface, on two perpendicular axes of the toric lens, form accuracy of 0.49 µm peak-to-valley (PV), and surface roughness of 12 nm in Ra, 4–8 nm in Sa are obtained. From the experimental results obtained, it can be concluded that the proposed method is a reasonable alternative for manufacturing toric lens mould.

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.

Investigation of Surface Roughness Prediction in Single-Point Diamond Turning

2010 ◽  
Vol 154-155 ◽  
pp. 856-861
Author(s):  
Qing Liang Zhao ◽  
Jun Yun Chen ◽  
Jian Luo
Keyword(s):  
Surface Roughness ◽  
Single Point ◽  
Surface Profile ◽  
Diamond Turning ◽  
Cutting Conditions ◽  
Previous Model ◽  
Displacement Sensor ◽  
Vibration Modes ◽  
Roughness Prediction ◽  
Improved Model

Experimental results indicate the previous theoretical model cannot predict well the surface roughness in single-point diamond turning on a precision lathe. In solving that, an improved model was presented in this paper. The difference between the previous model and the improved model is that the relative tool-workpiece vibration is measured before cutting operation using a capacitive displacement sensor in the previous model whilst the vibration is extracted from the measured surface profile in the improved model. The relative vibration was first studied under various cutting conditions to establish the vibration modes under corresponding cutting conditions. Then the surface roughness was predicted based on the vibration modes. The results prove that there is good agreement between the predicted values and measured values and the improved model is useful and reliable.

Ultra-Precision Turning Technology of Gold Cone in Fast Ignition

2013 ◽  
Vol 562-565 ◽  
pp. 147-151
Author(s):  
Guo Li ◽  
Yan Hua Huang ◽  
Wei Chao Tong ◽  
Guang Hui Yuan ◽  
Yang Tao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wall Thickness ◽  
Single Point ◽  
Fast Ignition ◽  
Diamond Turning ◽  
End Effect ◽  
Processing Parameter ◽  
Ultra Precision ◽  
Cone Surface

Fast Ignition (FI) attracts much attention owing to its advantages. The fabrication of fast ignition targets is one of the key technologies in FI study. Based on the single point diamond turning (SPDT) technology, Diamond post-turning method is adopted in this paper for the fabrication of gold cone. It not only helps to reduce the end-effect of cone mandrel and consequently improve the coaxiality of internal and external cone surface, but also helps to improve the quality of cone surface and the wall thickness consistency. Besides, the processing parameter of diamond post-turning is experimentally studied in this paper for its effect on the cone surface roughness. According to results, the cone surface roughness is Ra 9.21nm, the wall thickness consistency is 3μm and the cone end surface roughness is Ra5.72nm。

Forecasting of Surface Roughness and Cutting Force in Single Point Diamond Turning for KDP Crystal

2007 ◽  
Vol 339 ◽  
pp. 78-83 ◽  
Author(s):  
Jing He Wang ◽  
Shen Dong ◽  
H.X. Wang ◽  
Ming Jun Chen ◽  
Wen Jun Zong ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Cutting Force ◽  
Single Point ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Depth Of Cut ◽  
Kdp Crystal ◽  
Optimal Cutting Parameters

The method of single point diamond turning is used to machine KDP crystal. A regression analysis is adopted to construct a prediction model for surface roughness and cutting force, which realizes the purposes of pre-machining design, prediction and control of surface roughness and cutting force. The prediction model is utilized to analyze the influences of feed, cutting speed and depth of cut on the surface roughness and cutting force. And the optimal cutting parameters of KDP crystal on such condition are acquired by optimum design. The optimum estimated values of surface roughness and cutting force are 7.369nm and 0.15N, respectively .Using the optimal cutting parameters, the surface roughness Ra, 7.927nm, and cutting force, 0.19N, are obatained.

The Cutting Parameter Affecting to Surface Roughness in Single-Point Diamond Turning

2014 ◽  
Vol 887-888 ◽  
pp. 1236-1239
Author(s):  
Wang Hao ◽  
Yu Zhang ◽  
Qi Ming Xie
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Surface Finish ◽  
Diamond Tool ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Machining Process ◽  
Form Accuracy ◽  
Edge Sharpness

Single-point diamond turning (SPDT) is a machining process making use of a monocrystal diamond tool which possesses nanometric edge sharpness, form reproducibility and wear resistance. The process is capable of producing components with micrometre to submicrometre form accuracy and surface roughness in the nanometre range. The cutting parameters that can make an effect on surface finish and form accuracy of SPDT such as spindle speedfeed ratedepth of cut and so on.

Machinability Investigation of Reaction-Bonded Silicon Carbide by Single-Point Diamond Turning

2008 ◽  
Vol 389-390 ◽  
pp. 151-156 ◽  
Author(s):  
Zhi Yu Zhang ◽  
Ji Wang Yan ◽  
Tsunemoto Kuriyagawa
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Large Scale ◽  
High Efficiency ◽  
Low Cost ◽  
Single Point ◽  
Diamond Turning ◽  
Machining Process ◽  
Depth Of Cut ◽  
Material Microstructure

Reaction-bonded silicon carbide (RB-SiC) is a recently developed ceramic material with many merits such as low manufacturing temperature, dense structure, high purity and low cost. In the present paper, the precision machinability of RB-SiC was studied by microindentation and single-point diamond turning (SPDT) tests. The influence of depth of cut and tool feed rate on surface roughness and cutting force was investigated. Results showed that there was no clear ductile-brittle transition in machining behavior. The material removal mechanism involves falling of the SiC grains and intergranular microfractures of the bonding silicon, which prevents from large-scale cleavage fractures. The minimum surface roughness depends on the initial material microstructure in terms of sizes of the SiC grains and micro pores. This work preliminarily indicates that SPDT can be used as a high-efficiency machining process for RB-SiC.

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