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Process: Diamond Turning Is A Process of Mechanical
Process: Diamond Turning Is A Process of Mechanical
Process[edit]
Diamond turning is a multi-stage process. Initial stages of machining are carried
out using a series of CNC lathes of increasing accuracy. A diamond-tipped lathe
tool is used in the final stages of the manufacturing process to achieve sub-
nanometer level surface finishes and sub-micrometer form accuracies. The
surface finish quality is measured as the peak-to-valley distance of the grooves
left by the lathe. The form accuracy is measured as a mean deviation from the
ideal target form. Quality of surface finish and form accuracy is monitored
throughout the manufacturing process using such equipment as contact and
laser profilometers, laser interferometers, optical and electron microscopes.
Diamond turning is most often used for making infrared optics, because at longer
wavelengths optical performance is less sensitive to surface finish quality, and
because many of the materials used are difficult to polish with traditional
methods.
The diamonds that are used in the process are incredibly strong in the vertical
downward direction but very weak in the upward and sideways directions.
Materials[edit]
Diamond turning is specifically useful when cutting materials that are viable as
infrared optical components and certain non-linear optical components such
as KDP. KDP is a perfect material in application for diamond turning, because
the material is very desirable for its optical modulating properties, yet it is
impossible to make optics from this material using conventional methods. KDP is
water soluble, so conventional grinding and polishing techniques are not effective
in producing optics. Diamond turning works well to produce optics from KDP.
Plastics
Acetal
Acrylic
Nylon
Polycarbonate
Polypropylene
Polystyrene
Zeonex
Metals
Brass
Copper
Gold
Tin
Zinc
Infrared crystals
Cadmium sulfide
Cadmium telluride
Calcium fluoride
Cesium iodide
Gallium arsenide
Germanium
Lithium niobate
Potassium bromide
Silicon
Sodium chloride
Tellurium dioxide
Zinc selenide
Zinc sulfide
The most often requested materials that are not readily machinable are:[1]
Titanium
Molybdenum
Ferrous materials are not readily machinable because the carbon in the diamond
tool chemically reacts with the substrate, leading to tool damage and dulling after
short cut lengths. Several techniques have been investigated to prevent this
reaction, but few have been successful for long diamond machining processes at
mass production scales.
Quality control[edit]
Despite all the automation involved in the diamond turning process, the human
operator still plays the main role in achieving the final result. Quality control is a
major part of the diamond turning process and is required after each stage of
machining, sometimes after each pass of the cutting tool. If it is not detected
immediately, even a minute error during any of the cutting stages results in a
defective part. The extremely high requirements for quality of diamond-turned
optics leave virtually no room for error.