Diamond turning
Encyclopedia
Diamond turning is a process of mechanical machining
of precision elements using lathe
s or derivative machine tools (e.g., turn-mills, rotary transfers) equipped with natural or synthetic diamond
-tipped tool bit
s. The term single-point diamond turning (SPDT) is sometimes applied, although as with other lathe work, the "single-point" label is sometimes only nominal (radiused tool noses and contoured form tools being options). The process of diamond turning is widely used to manufacture high-quality aspheric
optical elements from crystal
s, metal
s, acrylic, and other materials. Optical elements produced by the means of diamond turning are used in optical assemblies in telescope
s, video projector
s, missile guidance
systems, lasers, scientific research instruments, and numerous other systems and devices. Most SPDT today is done with computer numerical control
(CNC) machine tools. Diamonds also serve in other machining processes, such as milling, grinding, and honing.
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 profilometer
s, laser interferometers, optical
and electron microscope
s.
base with micrometer surface finish quality. The granite base is placed on air suspension on a solid foundation, keeping its working surface strictly horizontal. The machine tool components are placed on top of the granite base and can be moved with high degree of accuracy using a high-pressure air cushion or hydraulic suspension. The machined element is attached to an air chuck
using negative air pressure and is usually centered manually using a micrometer. The chuck itself is separated from the electric motor that spins it by another air suspension.
The cutting tool is moved with nanometer precision by a combination of electric motors and piezoelectric actuators. The motion of the tool is controlled by a list of coordinates generated by a computer directly from a CAD
model in newer machines or by manually-generated machining code (usually G-Code
or a derivative) on older machines . The final surface is achieved with a series of cutting passes of decreasing depth.
Alternative methods of diamond machining in practice also include diamond fly cutting and diamond milling. Diamond fly cutting can be used to generate diffraction grating
s and other linear patterns with appropriately contoured diamond shapes. Diamond milling can be used to generate aspheric lens arrays by annulus cutting methods with a spherical diamond tool.
. 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.
Generally, diamond turning is restricted to certain materials. Materials that are readily machinable include:
The most often requested materials that are not readily machinable are:
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. Diamond turning is most often used in infrared wavelengths because of the materials, surface roughness, and pick distance for the tooling.
The SPDT manufacturing process produces a relatively high percentage of defective parts, which must be discarded. As a result, the manufacturing costs are high compared to conventional polishing methods. Even with the relatively high volume of optical components manufactured using the SPDT process, this process cannot be classified as mass production, especially when compared with production of polished optics. Each diamond-turned optical element is manufactured on an individual basis with extensive manual labor.
Machining
Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools, such as saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to physical remove material to achieve a desired...
of precision elements using lathe
Lathe
A lathe is a machine tool which rotates the workpiece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the workpiece to create an object which has symmetry about an axis of rotation.Lathes are used in woodturning,...
s or derivative machine tools (e.g., turn-mills, rotary transfers) equipped with natural or synthetic diamond
Diamond
In mineralogy, diamond is an allotrope of carbon, where the carbon atoms are arranged in a variation of the face-centered cubic crystal structure called a diamond lattice. Diamond is less stable than graphite, but the conversion rate from diamond to graphite is negligible at ambient conditions...
-tipped tool bit
Tool bit
The term tool bit generally refers to a non-rotary cutting tool used in metal lathes, shapers, and planers. Such cutters are also often referred to by the set-phrase name of single-point cutting tool. The cutting edge is ground to suit a particular machining operation and may be resharpened or...
s. The term single-point diamond turning (SPDT) is sometimes applied, although as with other lathe work, the "single-point" label is sometimes only nominal (radiused tool noses and contoured form tools being options). The process of diamond turning is widely used to manufacture high-quality aspheric
Aspheric lens
An aspheric lens or asphere is a lens whose surface profiles are not portions of a sphere or cylinder. In photography, a lens assembly that includes an aspheric element is often called an aspherical lens....
optical elements from crystal
Crystal
A crystal or crystalline solid is a solid material whose constituent atoms, molecules, or ions are arranged in an orderly repeating pattern extending in all three spatial dimensions. The scientific study of crystals and crystal formation is known as crystallography...
s, metal
Metal
A metal , is an element, compound, or alloy that is a good conductor of both electricity and heat. Metals are usually malleable and shiny, that is they reflect most of incident light...
s, acrylic, and other materials. Optical elements produced by the means of diamond turning are used in optical assemblies in telescope
Telescope
A telescope is an instrument that aids in the observation of remote objects by collecting electromagnetic radiation . The first known practical telescopes were invented in the Netherlands at the beginning of the 1600s , using glass lenses...
s, video projector
Video projector
A video projector is an image projector that receives a video signal and projects the corresponding image on a projection screen using a lens system. All video projectors use a very bright light to project the image, and most modern ones can correct any curves, blurriness, and other...
s, missile guidance
Missile guidance
Missile guidance refers to a variety of methods of guiding a missile or a guided bomb to its intended target. The missile's target accuracy is a critical factor for its effectiveness...
systems, lasers, scientific research instruments, and numerous other systems and devices. Most SPDT today is done with computer numerical control
Numerical control
Numerical control refers to the automation of machine tools that are operated by abstractly programmed commands encoded on a storage medium, as opposed to controlled manually via handwheels or levers, or mechanically automated via cams alone...
(CNC) machine tools. Diamonds also serve in other machining processes, such as milling, grinding, and honing.
Process
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-micrometerMicrometre
A micrometer , is by definition 1×10-6 of a meter .In plain English, it means one-millionth of a meter . Its unit symbol in the International System of Units is μm...
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 profilometer
Profilometer
Profilometer is a measuring instrument used to measure a surface's profile, in order to quantify its roughness.While the historical notion of a profilometer was a device similar to a phonograph that measures a surface as the surface is moved relative to the contact profilometer's stylus, this...
s, laser interferometers, optical
Microscope
A microscope is an instrument used to see objects that are too small for the naked eye. The science of investigating small objects using such an instrument is called microscopy...
and electron microscope
Electron microscope
An electron microscope is a type of microscope that uses a beam of electrons to illuminate the specimen and produce a magnified image. Electron microscopes have a greater resolving power than a light-powered optical microscope, because electrons have wavelengths about 100,000 times shorter than...
s.
The machine tool
For best possible quality natural diamonds are used as single-point cutting elements during the final stages of the machining process. A CNC SPDT lathe rests atop a high-quality graniteGranite
Granite is a common and widely occurring type of intrusive, felsic, igneous rock. Granite usually has a medium- to coarse-grained texture. Occasionally some individual crystals are larger than the groundmass, in which case the texture is known as porphyritic. A granitic rock with a porphyritic...
base with micrometer surface finish quality. The granite base is placed on air suspension on a solid foundation, keeping its working surface strictly horizontal. The machine tool components are placed on top of the granite base and can be moved with high degree of accuracy using a high-pressure air cushion or hydraulic suspension. The machined element is attached to an air chuck
Chuck (engineering)
A chuck is a specialized type of clamp used to hold an object, usually an object with radial symmetry, especially a cylindrical object. It is most commonly used to hold a rotating tool or a rotating workpiece...
using negative air pressure and is usually centered manually using a micrometer. The chuck itself is separated from the electric motor that spins it by another air suspension.
The cutting tool is moved with nanometer precision by a combination of electric motors and piezoelectric actuators. The motion of the tool is controlled by a list of coordinates generated by a computer directly from a CAD
Computer-aided design
Computer-aided design , also known as computer-aided design and drafting , is the use of computer technology for the process of design and design-documentation. Computer Aided Drafting describes the process of drafting with a computer...
model in newer machines or by manually-generated machining code (usually G-Code
G-code
G-code is the common name for the most widely used computer numerical control programming language, which has many implementations. Used mainly in automation, it is part of computer-aided engineering. G-code is sometimes called G programming language...
or a derivative) on older machines . The final surface is achieved with a series of cutting passes of decreasing depth.
Alternative methods of diamond machining in practice also include diamond fly cutting and diamond milling. Diamond fly cutting can be used to generate diffraction grating
Diffraction grating
In optics, a diffraction grating is an optical component with a periodic structure, which splits and diffracts light into several beams travelling in different directions. The directions of these beams depend on the spacing of the grating and the wavelength of the light so that the grating acts as...
s and other linear patterns with appropriately contoured diamond shapes. Diamond milling can be used to generate aspheric lens arrays by annulus cutting methods with a spherical diamond tool.
Materials
Diamond turning is specifically useful when cutting materials that are viable as infrared optical components and certain non-linear optical components such as KDPMonopotassium phosphate
Monopotassium phosphate -- 24 -- is a soluble salt which is used as a fertilizer, a food additive and a fungicide. It is a source of phosphorus and potassium. It is also a buffering agent...
. KDP
Monopotassium phosphate
Monopotassium phosphate -- 24 -- is a soluble salt which is used as a fertilizer, a food additive and a fungicide. It is a source of phosphorus and potassium. It is also a buffering agent...
is a perfect material in application for diamond turning, because the material is very desirable for its optical modulating
Optical modulator
An optical modulator is a device which is used to modulate a beam of light. The beam may be carried over free space, or propagated through an optical waveguide. Depending on the parameter of a light beam which is manipulated, modulators may be categorized into amplitude modulators, phase...
properties, yet it is impossible to make optics from this material using conventional methods. KDP is water soluble, so conventional grinding and polishing
Polishing
Polishing is the process of creating a smooth and shiny surface by rubbing it or using a chemical action, leaving a surface with a significant specular reflection In some materials polishing is also able to reduce diffuse reflection to...
techniques are not effective in producing optics. Diamond turning works well to produce optics from KDP.
Generally, diamond turning is restricted to certain materials. Materials that are readily machinable include:
- Plastics
- Acrylic
- PolycarbonatePolycarbonatePolycarbonatePhysical PropertiesDensity 1.20–1.22 g/cm3Abbe number 34.0Refractive index 1.584–1.586FlammabilityV0-V2Limiting oxygen index25–27%Water absorption – Equilibrium0.16–0.35%Water absorption – over 24 hours0.1%...
- NylonNylonNylon is a generic designation for a family of synthetic polymers known generically as polyamides, first produced on February 28, 1935, by Wallace Carothers at DuPont's research facility at the DuPont Experimental Station...
- AcetalAcetalAn acetal is a molecule with two single-bonded oxygen atoms attached to the same carbon atom.Traditional usages distinguish ketals from acetals...
- PolypropylenePolypropylenePolypropylene , also known as polypropene, is a thermoplastic polymer used in a wide variety of applications including packaging, textiles , stationery, plastic parts and reusable containers of various types, laboratory equipment, loudspeakers, automotive components, and polymer banknotes...
- PolystyrenePolystyrenePolystyrene ) also known as Thermocole, abbreviated following ISO Standard PS, is an aromatic polymer made from the monomer styrene, a liquid hydrocarbon that is manufactured from petroleum by the chemical industry...
- Zeonex
- Metals
- Aluminium alloyAluminium alloyAluminium alloys are alloys in which aluminium is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories...
s and purified aluminum - CopperCopperCopper is a chemical element with the symbol Cu and atomic number 29. It is a ductile metal with very high thermal and electrical conductivity. Pure copper is soft and malleable; an exposed surface has a reddish-orange tarnish...
- GoldGoldGold is a chemical element with the symbol Au and an atomic number of 79. Gold is a dense, soft, shiny, malleable and ductile metal. Pure gold has a bright yellow color and luster traditionally considered attractive, which it maintains without oxidizing in air or water. Chemically, gold is a...
- BrassBrassBrass is an alloy of copper and zinc; the proportions of zinc and copper can be varied to create a range of brasses with varying properties.In comparison, bronze is principally an alloy of copper and tin...
- Electroless nickelElectroless nickel platingElectroless nickel plating is an auto-catalytic chemical technique used to deposit a layer of nickel-phosphorus or nickel-boron alloy on a solid workpiece, such as metal or plastic. The process relies on the presence of a reducing agent, for example hydrated sodium hypophosphite which reacts with...
- SilverSilverSilver is a metallic chemical element with the chemical symbol Ag and atomic number 47. A soft, white, lustrous transition metal, it has the highest electrical conductivity of any element and the highest thermal conductivity of any metal...
- ZincZincZinc , or spelter , is a metallic chemical element; it has the symbol Zn and atomic number 30. It is the first element in group 12 of the periodic table. Zinc is, in some respects, chemically similar to magnesium, because its ion is of similar size and its only common oxidation state is +2...
- TinTinTin is a chemical element with the symbol Sn and atomic number 50. It is a main group metal in group 14 of the periodic table. Tin shows chemical similarity to both neighboring group 14 elements, germanium and lead and has two possible oxidation states, +2 and the slightly more stable +4...
- Aluminium alloy
- Infrared crystals
- Cadmium sulfideCadmium sulfideCadmium sulfide is the inorganic compound with the formula CdS. Cadmium sulfide is a yellow solid. It occurs in nature with two different crystal structures as the rare minerals greenockite and hawleyite, but is more prevalent as an impurity substituent in the similarly structured zinc ores...
- Cadmium tellurideCadmium tellurideCadmium telluride is a crystalline compound formed from cadmium and tellurium. It is used as an infrared optical window and a solar cell material. It is usually sandwiched with cadmium sulfide to form a p-n junction photovoltaic solar cell...
- Calcium fluorideCalcium fluorideCalcium fluoride is the inorganic compound with the formula CaF2. This ionic compound of calcium and fluorine occurs naturally as the mineral fluorite . It is the source of most of the world's fluorine. This insoluble solid adopts a cubic structure wherein calcium is coordinated to eight fluoride...
- Cesium iodide
- Gallium arsenide
- GermaniumGermaniumGermanium is a chemical element with the symbol Ge and atomic number 32. It is a lustrous, hard, grayish-white metalloid in the carbon group, chemically similar to its group neighbors tin and silicon. The isolated element is a semiconductor, with an appearance most similar to elemental silicon....
- Lithium niobateLithium niobateLithium niobate is a compound of niobium, lithium, and oxygen. Its single crystals are an important material for optical waveguides, mobile phones, optical modulators and various other linear and non-linear optical applications.-Properties:...
- Potassium bromidePotassium bromidePotassium bromide is a salt, widely used as an anticonvulsant and a sedative in the late 19th and early 20th centuries, with over-the-counter use extending to 1975 in the United States. Its action is due to the bromide ion...
- SiliconSiliconSilicon is a chemical element with the symbol Si and atomic number 14. A tetravalent metalloid, it is less reactive than its chemical analog carbon, the nonmetal directly above it in the periodic table, but more reactive than germanium, the metalloid directly below it in the table...
- Sodium chlorideSodium chlorideSodium chloride, also known as salt, common salt, table salt or halite, is an inorganic compound with the formula NaCl. Sodium chloride is the salt most responsible for the salinity of the ocean and of the extracellular fluid of many multicellular organisms...
- Tellurium dioxideTellurium dioxideTellurium dioxide is a solid oxide of tellurium. It is encountered in two different forms, the yellow orthorhombic mineral tellurite, β-TeO2, and the synthetic, colourless tetragonal , α-TeO2...
- Zinc selenideZinc selenideZinc selenide , is a light yellow binary solid compound. It is an intrinsic semiconductor with a band gap of about 2.70 eV at 25 °C. ZnSe rarely occurs in nature...
- Zinc sulfideZinc sulfideZinc sulfide is a inorganic compound with the formula ZnS. ZnS is the main form of zinc in nature, where it mainly occurs as the mineral sphalerite...
- Cadmium sulfide
The most often requested materials that are not readily machinable are:
- Silicon based glasses
- Ferrous materials (SteelSteelSteel is an alloy that consists mostly of iron and has a carbon content between 0.2% and 2.1% by weight, depending on the grade. Carbon is the most common alloying material for iron, but various other alloying elements are used, such as manganese, chromium, vanadium, and tungsten...
, IronIronIron is a chemical element with the symbol Fe and atomic number 26. It is a metal in the first transition series. It is the most common element forming the planet Earth as a whole, forming much of Earth's outer and inner core. It is the fourth most common element in the Earth's crust...
) - BerylliumBerylliumBeryllium is the chemical element with the symbol Be and atomic number 4. It is a divalent element which occurs naturally only in combination with other elements in minerals. Notable gemstones which contain beryllium include beryl and chrysoberyl...
- TitaniumTitaniumTitanium is a chemical element with the symbol Ti and atomic number 22. It has a low density and is a strong, lustrous, corrosion-resistant transition metal with a silver color....
- MolybdenumMolybdenumMolybdenum , is a Group 6 chemical element with the symbol Mo and atomic number 42. The name is from Neo-Latin Molybdaenum, from Ancient Greek , meaning lead, itself proposed as a loanword from Anatolian Luvian and Lydian languages, since its ores were confused with lead ores...
- NickelNickelNickel is a chemical element with the chemical symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel belongs to the transition metals and is hard and ductile...
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. Diamond turning is most often used in infrared wavelengths because of the materials, surface roughness, and pick distance for the tooling.
Quality control
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.The SPDT manufacturing process produces a relatively high percentage of defective parts, which must be discarded. As a result, the manufacturing costs are high compared to conventional polishing methods. Even with the relatively high volume of optical components manufactured using the SPDT process, this process cannot be classified as mass production, especially when compared with production of polished optics. Each diamond-turned optical element is manufactured on an individual basis with extensive manual labor.