Diamond Turning Technology

Introduction
 Ultra-precision machining using single crystal natural diamond tools
has been under development for about five decades.
 The technology development has experienced major advances in the
field of machine design, performance and productivity enhancement
in seventies.
 Ultra-precision machining techniques were successfully used for the
manufacture of computer memory discs used in hard drives and
photoreceptor components for photocopier machine and printer
applications during early seventies.
 These applications required extremely high geometrical accuracies
in combination with super-smooth surfaces.
 These surfaces were effectively manufactured by single point
diamond turning as opposed to multiple processes such as
machining, lapping and polishing.
DIAMOND TURNING MACHINE
 Diamond Turning Machine (DTM) is an ultra-
precision CNC turning machine.
 It consists of a horizontal axis work head spindle on
which the work piece is held by means of a vacuum
chuck.
 The work head spindle is mounted on a Z-slide
whereas tool post is mounted on X-slide.
 The movement of both the slides is controlled by CNC
system.
 All the machine sub-systems are assembled on top of a
vibration isolated granite base.
Special characteristics of a Diamond
Turning Machine
 DC linear motors provides rapid feed rates, smooth, wear-free, non-
influencing motion, and superb longitudinal dynamic stiffness.
 High speed air bearing spindles allow faster feed rates, therefore reduced
cycle times, as well as smooth rotational motion, high load capacity, and
stiffness.
 High speed CNC controls, utilizing PC technology, to allow networking,
huge part program storage, and utilization of third party programs. Also to
facilitate the use of advanced drive and feedback devices to improve work
piece accuracy.
 High-resolution linear scales, provide precise axis position feedback for
nanometric incremental moves, improved dimensional stability, and
ultimately, consistent and precise geometrical accuracy.
 On machine work piece measurement and error compensation system
allows residual work piece errors to be assessed, and practically
eliminated, providing they are of a repeatable nature.
DTM machine
Work head
The Work head houses the spindle and its integral drive.
The robust, high precision spindle runs on hydrostatic
bearings, which ensure high stiffness and damping, besides
providing exceptional rotational accuracy.
The inlet oil is temperature controlled for thermal stability.
The nose of the spindle facilitates mounting of the Vacuum
chuck.
Drive to the spindle is from a brush less direct drive motor
mounted integral with the spindle.
The spindle speed is steplessly variable.
The stator of the motor is cooled by a water jacket for thermal
stability.
Work head slide (Z-slide)
The work head slide is of rigid cast iron construction and is
guided on preloaded aerostatic or hydrostatic rectangular steel
guide ways, which ensure very precise and fine movement with
negligible stick-slip.
Drive to the slide is through a precision re-circulating ball
screw/nut arrangement and a servomotor. Present day machines
incorporate linear motors.

Tool slide (X-slide)

The tool slide is of rigid cast iron construction and is guided on
preloaded hydrostatic rectangular steel guide ways which ensure
very precise and fine movement with negligible stick slip.
Tool post
The tool post is a rigid unit for mounting the turning tool. The
tool post unit is mounted on top of a micro-height adjustment
platform. This micro-height adjustment platform aids in
centering the tool to the axis of rotation in the vertical
direction. The tool post has very high stiffness values typically
5,00,000 to 7,50,000 lb/inch.
Machine Base
The machine is built on a bed of solid epoxy granite. This
forms the accurate datum on which is mounted various sub-
systems of the machine. Granite provides excellent long-term
dimensional stability, good damping properties and thermal
stability.
Vibration Isolation System
The granite bed is placed on four self-leveling vibration
isolation legs that eliminate all the external vibrations down to
5 Hz, transmitted through the foundation. The machine can be
installed on a normal workshop floor and needs no anchoring.
Machine controls
The machine is provided with a CNC system with
integrated PLC. The CNC system is capable of
controlling two linear axes (X & Z-axes).
An integrated drive for the spindle whose speed is
controlled by the CNC system is also provided. All
motors are of the AC brush less type with direct
digital control.
High-resolution linear encoders are employed for
position feedback.
DIAMOND MACHINING MECHANISM
 Single point diamond turning is one of the most important processes
used for micro cutting. This is an extreme technology capable of
material removal to even nanometric scale.
 When chip size becomes less than about one micrometer, the shear
stress in the cutting tool increases sharply and becomes very large.
This is due to the fact that with the depth of cut less than one
micrometer, the distribution of movable dislocations in the metal
crystals approaches zero and thus the cutting forces have to
overcome very large atomic bonding forces within the crystals.
 In a typical case, a single point diamond tool with nose radius of
approximately 5 µm being used to cut a mirror surface in oxygen
free copper at a feed rate of 0.5 m to 2m per revolution and depth
of cut of approximately 5m. This can produce surface roughness of
about 20 nm with a "degenerated surface layer" of less than 1 m.
DIAMOND TOOL
When using advanced two axis-machining methods, as is the
case for general diamond turning, the type of tool utilized
requires careful consideration.
Final work piece accuracy is dictated by several error
sources, including the machine inherent precision, fixturing,
tool setting, environmental conditions and tool waviness.
By using high accuracy controlled waviness tools the
contour accuracy is predictably high.
The standard waviness value for electro-optics tool is less
than 0.25 µm.
However, special tools with less than fifty nanometer
waviness are available for specific applications.
Top rake surface of the tool is oriented along specified plane
of the diamond crystal, which is the hardest surface in the
crystal.
The tool tip is ground to shape on specially developed ultra-
precision tool grinding and lapping machines.
The tool is finally sharpened using ion beam etching to get
ultra sharp cutting edges.
Conclusion
 Diamond Turning Machines are extremely precise and
their application areas are widening.
 Presently, the optical lenses and other ultra precision
components use DTM technology extensively.
 The use of these machines in this country is expected to
grow fast in the next few years.