Modares Mechanical Engineering

Modares Mechanical Engineering

Study on the ultra-precision dimond machining to fabricate Aluminium mirrors

Document Type : Original Research

Authors
Hojjat Jafari 1
Sadegh Elhami 2
Masoud Farahnakian 1
1 Najafabad Branch, Islamic Azad University, Najafabad, Iran.
2 Ferdowsi University of Mashhad
10.22034/mme.23.5.283
Abstract
Metal and especially aluminum mirrors have wide applications in the optical industry due to their desirable properties, hence requiring very high polished surfaces. One of the methods of preparing aluminum mirrors is single-point diamond turning. In this research, the manufacturing process of 6061-grade aluminum mirrors has been studied using diamond turning and consequent polishing process in order to reach surfaces with acceptable optical properties. In the first part, the effective range of turning parameters was determined. The results showed that the feed values less than 5 µm/rev, the cutting edge radius between 0.2 and 0.8 mm, and the rotational speed of 2250 rpm have a greater effect on the surface roughness. In the second part of the research, initially, the turning process was performed with effective parameters and then the polishing process was applied as the final finishing process. Surface finish is evaluated by surface roughness and surface interferometry parameters. The results showed that the smaller surface roughness after the diamond tool turning process led to higher optical properties after the final polishing process. The lowest PV value equal to 0.293 µm was obtained by diamond turning with 1.5 µm/rev and a cutting edge radius of 0.8 mm.
Keywords
Aluminium Mirror
Diamond Turning
Polishing
Surface roughness
Interferometry

Subjects

1- S. To , W.B. Lee, and C.Y. Chan, Ultra precision Diamond Turning of Aluminum Single Crystals, The Hong Kong Polytechnic University, 63 (1997) 157-162
2- Cheung CF, Lee WB. Characterisation of nanosurface generation in single-point diamond turning. International Journal of Machine Tools and Manufacture. 2001 May 1;41(6):851-75.
3- F Z FANG, X D LIU and L C LEE, Micro-machining of optical glasses – A review of diamond-cutting glasses, Singapore Institute of Manufacturing Technology, 2003, pp. 945–955.
4- Maxence Bigerelle a, Alexis Gautier a, Alain Iost, Roughness characteristic length scales of micro machined surfaces: A multi-scale modeling, 2006, Sensors and Actuators B 126 (2007) 126–137
5- Lee WB, Cheung CF, To S. Multi-scale modeling of surface topography in single-point diamond turning. InKey Engineering Materials 2007 (Vol. 340, pp. 1009-1016). Trans Tech Publications Ltd.
6- Childs TH, Sekiya K, Tezuka R, Yamane Y, Dornfeld D, Lee DE, Min S, Wright PK. Surface finishes from turning and facing with round nosed tools. CIRP annals. 2008 Jan 1;57(1):89-92.
7- Rik ter Horsta, Menno de Haana, Guido Gubbelsb, Roger Sendenb, Bart van Venrooyc,André Hoogstratec, DIAMOND TURNING AND POLISHING TESTS ON NEW RSP ALUMINIUM ALLOYS, NOVA Optical- Infrared Instrumentation Group at ASTRON,2012, Vol. 8450, 84502M
8- Shah SC, Geroge PM. Surface roughness modeling in precision turning of aluminium by polycrystalline diamond tool using response surface methodology. Int J Emerge Technol Adv Eng. 2012 May;2:41-5.
9- Shen Z, Yu J, Song Z, Chen L, Yuan Q, Gao Z, Pei S, Liu B, Ye J. Customized design and efficient fabrication of two freeform aluminum mirrors by single point diamond turning technique. Applied Optics. 2019 Mar 20;58(9):2269-76.
10- Xie Y, Mao X, Li J, Wang F, Wang P, Gao R, Li X, Ren S, Xu Z, Dong R. Optical design and fabrication of an all-aluminum unobscured two-mirror freeform imaging telescope. Applied Optics. 2020 Jan 20;59(3):833-40.
11- Hatefi S, Abou-El-Hossein K. Review of single-point diamond turning process in terms of ultra-precision optical surface roughness. The International Journal of Advanced Manufacturing Technology. 2020 Jan;106:2167-87.
12- He S, Xuan J, Du W, Xia Q, Xiong S, Zhang L, Wang Y, Wu J, Tao H, Shi T. Spiral tool path generation method in a NURBS parameter space for the ultra-precision diamond turning of freeform surfaces. Journal of Manufacturing Processes. 2020 Dec 1;60:340-55.
13- Nagayama K, Yan J. Measurement and compensation of tool contour error using white light interferometry for ultra-precision diamond turning of freeform surfaces. International Journal of Automation Technology. 2020 Jul 5;14(4):654-64.
14- Wang T, Wu X, Zhang G, Dai Y, Xu B, Ruan S. An experimental study on single-point diamond turning of a 55 vol% SiCp/Al composite below the ductile brittle transition depth of SiC. The International Journal of Advanced Manufacturing Technology. 2020 Jun;108:2255-68.
15- Wang J, Zhang G, Chen N, Zhou M, Chen Y. A review of tool wear mechanism and suppression method in diamond turning of ferrous materials. The International Journal of Advanced Manufacturing Technology. 2021 Apr;113:3027-55.
16- Wyant JC, Creath K. Basic wavefront aberration theory for optical metrology. Applied optics and optical engineering. 1992 Jan 1;11(part 2):28-39.
17- Dabiri S, Dehghan O, Shamekhi M. Matrix in optics. Paya Group. 2010 (In Persian).
Modares Mechanical Engineering
Volume 23, Issue 5
April 2023
Pages 283-292