n South African Journal of Industrial Engineering - Quality of silicon convex lenses fabricated by ultra-high precision diamond machining

Volume 24, Issue 1
  • ISSN : 1012-277X



Infra-red optical components are made mainly from hard and brittle materials such as germanium and silicon. Silicon machining is characterised by some difficulties when ultra-high precision machined by mono-crystalline single-point diamond. Accelerated tool wear and machined-surface deterioration may take place if the machining parameters are not properly selected. In this study, we conducted a machining test on an ultra-high precision machine tool, using ductile regime cutting conditions when fabricating a convex surface on a silicon lens of aperture of 60 mm diameter, and using a mono-crystalline diamond. It was found that the cutting conditions for shaping a convex surface of 500 mm radius resulted in good form accuracy. However, more attention should be paid to optimising the holding force of the vacuum chuck employed.

Infrarooi optiese komponente word hoofsaaklik van harde, bros materiale soos germanium en silikon gemaak. Ultra-hoë akkurate masjinering van silikon met 'n mono-kristallyne enkelpunt diamantbeitel gee aanleiding tot verskeie probleme. Versnelde beitelslytasie en degradering van die masjineringsoppervlak kan plaasvind indien die masjineringsparameters nie behoorlik gekies word nie. In hierdie studie het ons 'n masjineringstoets uitgevoer met 'n ultra-hoë akkurate masjineringstelsel, waar rudraaiwerk gebruik is om die konvekse oppervlak van 'n silikonlens met 'n 60 mm opening met 'n mono-kristallyne enkelpunt diamantbeitel te masjineer. Daar is bevind dat die snytoestande wat gebruik is om die konvekse oppervlak met 500 mm radius te vorm, tot goeie vorm-akkuraatheid gelei het. Meer aandag moet egter gegee word aan die optimering van die vashoukrag van die vakuum-kloukop wat gebruik word.

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