Higher quality and reliability of products is the main demand of manufacturing industries. Ultra-precision machining is the efficient technique to produce highly precise surface with complex shapes and micro-features. Surface quality in ultra-precision machining is only assured by strictly following the optimized process conditions. This chapter covers the various stages of the ultra-precision diamond turning process especially considering the practical aspects. This chapter provides the understanding of, importance and effects of each stage of ultra-precision machining including metrology.

Ultra-precision Diamond Turning Process

L'objet de ce travail, realise entre Thales-Angenieux et l'Ecole Nationale Superieure des Mines de Saint-Etienne dans le cadre d'une convention CIFRE, porte sur l'analyse et la caracterisation de defauts apparaissant lors des differentes phases de fabrication de lentilles aspheriques en fluorine. Les lentilles ainsi realisees doivent etre integrees dans des produits et, de ce fait, ne doivent pas presenter de defauts genants. La fluorine est une matiere de plus en plus utilisee en optique de precision du fait de ses caracteristiques de transmission. La realisation de dioptres aspheriques dans cette matiere est d'autant plus complexe. La fabrication de ces surfaces peut se faire de diverses facons. Des methodes traditionnelles de polissage ou basees sur la microrectification et sur le tournage a l'outil diamant sont couramment utilisees. Cette derniere, relativement plus facile, plus rapide a mettre en œuvre et de cout moindre, donne neanmoins des surfaces inacceptables, non pas en terme de forme et de rugosite, mais des zones d'arrachement apparaissent sur le dioptre. Les moyens de mesure standard : profilometrie mecanique, deflectometrie, interferometrie sous rayonnements visibles monochromatique et polychromatique utilises generalement a chaque etape de ces processus deviennent alors insuffisants et ne permettent pas d'expliquer l'origine de ces arrachements. Une etude de la structure cristallographique par diffraction des rayons X ainsi qu'une interpretation des resultats par un logiciel d'analyse d'images permet alors d'expliquer ce phenomene et de relier l'orientation du monocristal de fluorine a la realisation de dioptres sans defauts. Ainsi il devient possible de remonter aux conditions d'usinage, de les modifier dans le but d'obtenir des surfaces exemptes de tout defaut.

https://tel.archives-ouvertes.fr/tel-00799798/document

Caractérisations quantitatives 3D à l'échelle nanométrique de l'extrême surface de lentilles à dioptres asphériques par analyse d'images.

/pdf/integrated-inspection-for-precision-part-production-3fivagzblo.pdf

Integrated Inspection for Precision Part Production

This paper reports on the technology required to produce deep-sag aspherical profiles, such as those found in optical mold inserts. To fabricate such inserts, the diamond tool has to be tilted sufficiently to achieve an effective flank angle of around 30 degrees. The maximum flank angle should be kept lower than 15 degrees to ensure adequate strength of the tool cutting edge. Due to the tool tilt, two types of form errors have to be addressed: the form error arising from the presented tool nose changing from circular to elliptical curvature, and the cone form error caused by the tool flank interfering with the center portion of the machined profile. The first type of form error can be eliminated by using a tool path correction procedure. For the second type of form error, theoretical and experimental investigations were conducted to determine the effects of the diamond tool tilt, the rotated angle and the tool nose radius on the center cone form error. This produces information on the correct tool radius and rotated angle required to minimize the center cone form error. With the above two procedures, the form error of deep-sag aspherical profiles can be improved significantly from 22 /spl mu/m to 0.11 /spl mu/m.

Ultraprecision turning of aspherical profiles with deep sag

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Ultraprecision turning of aspherical profiles with deep sag