Review of hybrid methods and advanced technologies for in-process metrology in ultra-high-precision single-point diamond turning

Hatefi, Shahrokh; Abou-El-Hossein, Khaled

doi:10.1007/s00170-020-06106-y

Cited by 13 publications

(7 citation statements)

References 134 publications

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“…Hybrid methods, or non-conventional machining, involves removal of processing disturbances by means of automatic metrology and control systems [18] or ultrasonic vibration control [19] to produce higher quality of optical surfaces [20]. Dynamic systems attempt to remove processing disturbances during mechanical contacts between the tool and workpiece [20].…”

Section: Hybrid Methodsmentioning

confidence: 99%

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

Mbangu Tambwe,

Pons

2024

JMMP

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Context—Rapidly solidified aluminium alloy (RSA 443) is increasingly used in the manufacturing of optical mold inserts because of its fine nanostructure, relatively low cost, excellent thermal properties, and high hardness. However, RSA 443 is challenging for single-point diamond machining because the high silicon content mitigates against good surface finishes. Objectives—The objectives were to investigate multiple different ways to optimize the process parameters for optimal surface roughness on diamond-turned aluminium alloy RSA 443. The response surface equation was used as input to three different artificial intelligence tools, namely genetic algorithm (GA), particle swarm optimization (PSO), and differential evolution (DE), which were then compared. Results—The surface roughness machinability of RSA443 in single-point diamond turning was primarily determined by cutting speed, and secondly, cutting feed rate, with cutting depth being less important. The optimal conditions for the best surface finish Ra = 14.02 nm were found to be at the maximum rotational speed of 3000 rpm, cutting feed rate of 4.84 mm/min, and depth of cut of 14.52 µm with optimizing error of 3.2%. Regarding optimization techniques, the genetic algorithm performed best, then differential evolution, and finally particle swarm optimization. Originality—The study determines optimal diamond machining parameters for RSA 443, and identifies the superiority of GA above PSO and DE as optimization methods. The principles have the potential to be applied to other materials (e.g., in the RSA family) and machining processes (e.g., turning, milling).

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Section: Hybrid Methodsmentioning

confidence: 99%

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

Mbangu Tambwe,

Pons

2024

JMMP

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“…The cutting force can be monitored as a signal for monitoring tool wear and surface defects [8]. It is important to measure the cutting force during the cutting process and determine the optimum cutting parameters and machining conditions [9][10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

“…It is important to have a real-time measurement of cutting force with a high sampling rate, as well as a quick response of the measurement system. The measurement system should have high precision, reliability, resolution, and repeatability [13,[22][23][24][25][26][27][28].…”

Section: Introductionmentioning

confidence: 99%

“…To enable an ideal hybrid machining platform for SPDT applications, it is necessary to use a high-performance force measurement system with a high frequency and quick response for the in-process metrology of applied force with high precision, resolution, and repeatability. In a hybrid SPDT platform, the force measurement system should be capable of real-time sampling while communicating and transmitting the acquired data to the hybrid controller for process optimization [13,[29][30][31].…”

Section: Introductionmentioning

confidence: 99%

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Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning

Hatefi,

Smith

2023

Micromachines

Self Cite

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Ultra-high-precision single-point diamond turning (SPDT) is the state-of-the-art machining technology for the advanced manufacturing of critical components with an optical surface finish and surface roughness down to one nanometer. One of the critical factors that directly affects the quality of the diamond-cutting process is the cutting force. Increasing the cutting force can induce tool wear, increase the cutting temperature, and amplify the positioning errors of the diamond tool caused by the applied cutting force. It is important to measure the cutting force during the SPDT process to monitor the tool wear and surface defects in real time. By measuring the cutting force in different cutting conditions, the optimum cutting parameters can be determined and the best surface accuracies with minimum surface roughness can be achieved. In this study a smart cutting tool for in-process force measurement and nanopositioning of the cutting tool for compensating the displacements of the diamond tool during the cutting process is designed and analyzed. The proposed smart cutting tool can measure applied forces to the diamond tool and correct the nanometric positioning displacements of the diamond tool in three dimensions. The proposed cutting tool is wireless and can be used in hybrid and intelligent SPDT platforms to achieve the best results in terms of optical surface finish. The simulation results are shown to be almost consistent with the results of the derived analytical model. The preliminary results pave the way for promising applications of the proposed smart cutting tool in SPDT applications in the future.

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“…However, KDP is very difficult to cut and polish, because the optical material is crisp, soft and easy to dissolute at atmosphere 7 – 9 . Currently, the only practical precise KDP machining technique is single-point diamond turning (SPDT) 10 – 12 . However, this method inevitably generates some microcosmic grooves, scratches and cracks on the crystal surface, and thus deteriorates the optical properties of KDP 13 – 15 .…”

Section: Introductionmentioning

confidence: 99%

Novel abrasive-free jet polishing for Bulk single-crystal KDP with a low viscosity microemulsion

Zhang

Fan

Gao

et al. 2022

Sci Rep

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In present work, the abrasive-free jet polishing (AFJP) of bulk single-crystal KDP was first fulfilled, when using a newly-designed low-viscosity microemulsion as the AFJP fluid. The novel AFJP fluid shows a typical water-in-oil structure, in which the water cores uniformly distribute in the BmimPF6 IL, with a particle size of about 20–25 nm. What’s more, the AFJP fluid is a controllable and selective non-abrasive jet fluid that the shape of the removal function is regular and smooth, presenting a similar Gaussian function, meanwhile, the dispersion coefficient of the removal rate is only 1.9%. Finally, the surface quality of the bulk single-crystal KDP is further improved by AFJP, meanwhile, the subsurface damage is first obviously mitigated.

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Review of hybrid methods and advanced technologies for in-process metrology in ultra-high-precision single-point diamond turning

Cited by 13 publications

References 134 publications

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

Optimization of Surface Roughness of Aluminium RSA 443 in Diamond Tool Turning

Design and Analysis of Ultra-Precision Smart Cutting Tool for In-Process Force Measurement and Tool Nanopositioning in Ultra-High-Precision Single-Point Diamond Turning

Novel abrasive-free jet polishing for Bulk single-crystal KDP with a low viscosity microemulsion

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