Single Point Diamond Research Articles

Ultrasonic-assisted ultra-precision turning of zinc-selenide with straight-nosed diamond tools

This study proposes a novel ultra-precision machining technology that uses ultrasonic vibration and a straight-nosed diamond tool to improve the processing of the brittle optical material zinc selenide (ZnSe). This research addresses the challenges posed by Poisson's effect in ultrasonic vibration-assisted single-point diamond turning, which causes bending vibration along the depth of cut, resulting in lower machining efficiency and surface quality. This study analyses the relationship between one-dimensional ultrasonic vibrations at the diamond tool edge and induced bending vibrations using both theoretical and experimental methods. By investigating ultrasonic vibration dynamics in the feed direction and at the straight cutting edge, the results showed that ultrasonic vibration helps to improve the ductile-brittle transition ratio of the cutting area and surface quality. These improvements are accomplished by regulating the cutting position at the tool cutting edge, adjusting cutting parameters, and optimizing ultrasonic parameters. The machined surface roughness of ZnSe is reduced by approximately 30-46% at higher feed rates under ultrasonic vibration with straight-nosed diamond tools. The findings demonstrate the potential of this novel technology to reduce tool wear and brittle fractures, resolving the challenge of ultra-precision machining for optical materials.

Deformation and optical aberration prediction in ultra-precision Single Point Diamond Turning of optical components

Aluminum is the material of choice for the majority of aerospace components, and, in the past few years, its application has been extended also to the mirrors of space telescopes because of the improved thermal behavior and the possibility to build the entire telescope with the same material. However, the low elastic modulus of such material, combined with the extremely tight tolerances of optical applications, make the production of these components very challenging and, usually, based on a trial-and-error approach. This paper presents a structured methodology for the prediction of the results of manufacturing in Single Point Diamond Turning of optical components, both in terms of absolute deformation as well as optical aberrations (via Zernike polynomials). All the most significant parameters acting on the workpiece have been simulated and combined. The proposed approach has been experimental validated on an actual aluminum mirror, proving its good accuracy (<5 % rms error). While some improvement can be performed to better match the experimental data in terms of Zernike coefficients, especially for non-symmetric aberrations, this paper forms the basis for an off-machine optimization of the SPDT process, drastically reducing the trial-and-error efforts.

Research on Textured Polishing Wheel (TPW) patterns for polishing dental ceramic materials in anhydrous environments

Abstract Dental ceramics commonly utilize high-hardness fused silica materials for the fabrication of inlays, crowns, and artificial dental implants, with their processing efficiency and surface roughness (Ra) directly influencing manufacturing costs and product quality. This study presents the development of a Textured Polishing Wheel (TPW) featuring three distinct surface patterns (spiral, linear, and radial), achieved through single-point diamond and pulsed laser processing techniques. It investigates the effects of these patterns on the removal rate and surface roughness (Ra) of dental ceramics during the polishing process. Results indicate that while TPW demonstrates comparable material removal depth to non-textured polishing wheels, it marginally increases surface roughness (Ra). Moreover, TPW significantly reduces burning and wear on the wheel surface during polishing. Pulsed laser ablation of TPW leads to further improvement in surface roughness, thereby enhancing the processing of dental ceramics. Experimental findings highlight the superior performance of spiral TPW, achieving a material removal rate of 4.2 μm/h and a surface roughness (Ra) of approximately 2.2 nm , thus meeting the manufacturing and functional requirements of dental ceramics.

Mid-spatial frequency reduction via zero-depth of cut rapid-feed passes in face-turning

The single point diamond turning process (SPDT) is used widely in creating optical grade mirror surfaces on several engineering materials ranging from polymers, and metals, to brittle materials such as silicon and germanium. In visual optic mirror applications, mid-spatial frequency (MSF) errors generated during the SPDT process interfere with the visible spectrum of light thereby affecting the image quality. To overcome these errors, a post-processing operation of polishing the optical mirrors is required. The post-processing step not only increases the complexity of the manufacturing process but also leads to minor geometrical form changes in the mirror which affects performance. To avoid post-processing and minimize MSFs formed during turning- a novel method to modify the toolpath during the machining process has been proposed in this paper. The suggested toolpath strategy comprises two consecutive operations: i) employing variable low feed rates with the specified depth of cut (DoC) and ii) executing rapid traverse rates with zero depth of cut for a predetermined number of passes. The effectiveness of the proposed strategy is tested by carrying out facing experiments in a micro-precision CNC lathe. The power spectral density (PSD) content of the machined surface is then analyzed to check for any improvement in the frequency characteristics. The results show that the frequency errors generated by the toolpath in normal turning operations can be minimized, distributing the resulting PSD peak over a wide range of spatial frequencies. From the PSD plots, it is observed that there is a decrease of 77% and 85.82% in the peak intensity values when compared with surfaces machined at constant feedrates of 150 μm/rev and 200 μm/rev respectively. This method can be applied to nanoprecision SPDT machines to improve the surface quality and to eliminate the MSF errors of the visual optical grade mirrors without the need for post-processing.

Influence of forging pretreatments on microstructure evolution and surface roughness of Al 6061 alloy

Achieving ultra-smooth surfaces is the goal of aluminum optical manufacturing. Under certain processing conditions, improving the microstructure of aluminum and understanding its relationship with surface roughness requires systematic study. The grain structure and various types of second-phase particles are of paramount importance. This study analyzed the microstructure of 6061 alloy after undergoing severe plastic deformation under various processing conditions followed by T6 homogenization heat treatment. Utilizing a white light interferometer, a comparative analysis of the surface roughness was conducted on specimens that underwent single-point diamond turning to achieve a mirror finish. The assessment of surface roughness on machined surfaces is solely based on white light interferometry. The analysis and discussion focus on the effects of phases (causing scratches and voids), the grains and grain boundaries. Experimental findings signify: the grain size, grain boundary and residual second phase can both influence the surface quality, the increase in deformation temperature and accumulated strain both facilitate the dissolution and fragmentation of the secondary phases. However, they also contribute to some extent to grain growth, resulting in a minimum secondary phase area fraction of 0.87% and grain sizes reaching 147.8 μm. Subsequent heat treatments, while effective in reducing the negative impact of the phases, reveal noticeable step-like structures affecting the quality of surface roughness, with the lowest obtained Ra value being 0.8 nm. A proposed pretreatment method in cleaner ingot processing with lower alloy element content addresses the trade-off between reducing phases and controlling grain growth, aiming to achieve improved surface roughness, promoting the application of polycrystalline aluminum alloys in the field of optics manufacturing.

Study of stress-assisted nano-cutting mechanism of gallium arsenide

The high-performance manufacturing of hard-brittle materials by single-point diamond turning (SPDT) is a very active and challenging research area. The stress-assisted nano-cutting is a promising method for improving the machinability of hard-brittle materials. However, the simulation results in the existing stress-assisted nano-cutting model would contradict the actual condition due to the pre-stress being released before tool entry into the workpiece. A modified stress-assisted nano-cutting model with a virtual boundary between the workpiece and tool is proposed for the first time in this paper to investigate the nano-cutting process of GaAs material under different external stresses. The emergence of an atomic flow vortex during stress-assisted nano-cutting significantly enhances the quality of the machined surface, leading to a substantial reduction in both machined surface roughness (34.4 %) and subsurface damage (56.2 %), compared to the normal nano-cutting. By evaluating surface roughness, subsurface damage depth, morphological accuracy, cutting force, and removal efficiency, a pre-strain of 0.06 is determined to be the optimal pre-strain for stress-assisted nano-cutting. Moreover, the selection of optimal pre-strain remains unaffected by variations in the nano-cutting depth. TEM results demonstrate that the nano-cutting mechanism elucidated by the MD analysis accurately reflects the genuine deformation of the GaAs material.

A novel tool path planning method for 5-axis single-point diamond turning

5-Axis single-point diamond turning adds two linked axes based on 3-axis single-point diamond turning, which can smoothly and continuously process complex surfaces. Compared to 3-axis turning, tool path planning for 5-axis single-point diamond turning is a complex decision-making process, which is a novel problem in the existing studies and a difficulty in multi-axis turning. In this study, a novel path planning method for 5-axis single-point diamond turning is proposed. Firstly, the mapping relation from scallop height to the distribution of cutter contact (CC) points is established in the non-uniform rational B-spline (NURBS) parameter space, thereby the planning of CC points is quickly achieved under fewer constraints. Furthermore, the local interference and global interference generation mechanism of 5-axis single-point diamond turning are revealed by geometrical analysis, combining diamond tool parameters and tool shank parameters. By transforming the motion of the cutter axis posture in 3D space into swings in two planes, the posture accessibility diagram of the cutter axis is efficiently constructed. Finally, the feasibility and effectiveness of the tool path planning method are verified by 5-axis single-point diamond turning experiment. And the contour accuracy is improved through the quadratic planning of the CC points (the contour accuracy after compensation is 3.2 μm compared to normal one 9.6 μm). This study extends the traditional 3-axis turning to 5-axis turning, providing a new perspective for the machining of complex surfaces.

Simplifying tailored generation of complex structured femtosecond pulses with easily fabricated phase plates.

This article presents a novel approach to targeted 4f pulse shaping using phase plates fabricated by single-point diamond turning (SPDT) machining. The manufacturing of the phase plates using SPDT is versatile, cost-effective, fast, robust, and applicable across a wide range of optical materials, spanning from visible to far-infrared spectra (e.g., PMMA, ZnSe). Manufactured profiles can be used for phase manipulation and pulse structuring, analogously to programable spatial light modulators (SLM). We demonstrate that the pulse waveforms can be reproduced with high fidelity by simple simulations based on calculating optical path differences induced by the phase plate for each wavelength and taking into account the finite focal spot. The simulated and reconstructed frequency-resolved optical gating spectrograms featured G errors between 1-2% and intensity errors between 0.02-0.06. Even for complex structured pulses with the rms value of the time-bandwidth product reaching 12, our method maintains high precision, in some cases even reaching lower G error compared to simpler waveforms. Finally, we also show that the phase plate can be used to attain a set of uncorrelated pulse waveforms by moving the plate relatively to the dispersed laser spectrum. Overall, this approach bypasses common limitations associated with pulse shaping using SLMs, such as pixelation, pixel cross-talk, and spectral or laser fluences constraints.

On-machine correction of form error for structured surfaces with anisotropic diffusion filter

Structured surfaces with high aspect ratio are promising in optical components, healthcare devices, and microelectronics. A preferable method to create precise structured surfaces is using single point diamond turning with on-machine surface measurement (OMSM). However, fabricating these surfaces often pose challenges due to steep gradients and discontinuous slopes, leading to significant form errors in machining. We propose an innovative solution by employing partial differential equation (PDE) filtration in a closed loop compensation process to enhance form accuracy and surface roughness compared to traditional methods. We tackle the problem of over-smoothing induced profile error encountered with traditional Gaussian filters. The proposed compensation strategy adapts to surface curvature and reduces instrument noise during on-machine measurements. Experimental of fabricating a segment spherical artefact, demonstrate improved precision. After adopting the proposed method, the form error is reduced from 1.2 µm to 0.5 µm and vibration ripples are mitigated, and a better surface finish is achieved.

Non-interference slow tool servo turning method for complex surfaces with large undulation changes

Complex curved surface parts are integral to the mechanical industry, demanding precise machining techniques. Multi-axis slow tool servo turning has emerged as an efficient method due to its high precision and quality. However, the challenge of severe tool flank interference arises, especially on surfaces with large undulation changes. Conventional methods, such as increasing tool clearance angles or adding extra tool axes, detrimentally affect machining precision and stability. To address this, a non-interference toolpath planning method is proposed for complex surfaces with large undulation changes. The approach begins with establishing geometric models of the single-point diamond turning tool and typical complex surfaces, followed by analyzing the mechanism and evolution of tool flank interference. By considering geometric parameters and vector relationships, the practical tool clearance angles are calculated. And then a criterion for subregion division is introduced and the non-cutting stroke is designed, accounting for the maximal acceleration of machine tool axis. Multi-pass toolpaths are generated to navigate different subregions while avoiding interference by transforming spindle rotation direction. Furthermore, a method is proposed to optimize toolpath stitching in practical machining regions, ensuring continuous and smooth transitions while maintaining machining precision and surface quality. Experimental validation, conducted on a hyperbolic paraboloid surface with large undulation changes, demonstrates a significant reduction in surface roughness (Sa) from 380.503 nm to 75.664 nm—a reduction of 80.115 %. The proposed method not only enhances machining precision and surface quality but also extends tool life and improves working conditions. This research offers vital guidance for non-interference toolpath planning in engineering practice.

Facile fabrication of hierarchical micro/nano aluminum alloy surfaces with enhanced hydrophobicity and surface quality by single point diamond cutting under a magnetic field influence

This study proposes an effective fabrication method for creating a hierarchical micro/nano structured aluminum alloy surface to enhance its hydrophobicity through single point diamond cutting using magnetophoresis. Magnetophoresis is a technique that manipulates metallic particles in metallic fluids using magnetic fields, and this study applies it to single-point diamond cutting by incorporating permanent magnets into the machining setup. The main grooves are cut to create a nano-grooved pattern on the first layer of the surface, while secondary grooves are cut on top of the first layer to form a micro pattern on the surface for two samples, one with and one without magnetophoresis. For magnetophoresis-fabricated samples, the first and second layers are cut in the presence of a magnetic field that is oriented perpendicular to the cutting direction of the first layer. Atomic force microscopy and an optical surface profiler reveal that the metallic marks appear on the surfaces that are parallel to the applied magnetic field for the magnetophoresis sample, which have been integrated with nano grooves to form a nano-textured surface on top of the microstructures. The sample fabricated under the influence of a magnetic field with magnetophoresis exhibits improved surface hydrophobicity, quality, and durability. This study highlights that magnetophoresis has the potential to fabricate metallic hydrophobic surfaces more efficiently than traditional methods for hierarchical micro/nano structured metallic surfaces, given that it does not necessitate the use of complex machining systems or advanced equipment.

Surface and subsurface response to the in-situ laser assistance in ultra-precision diamond turning of SiCp/Al composites

This study focuses on the application of in-situ laser-assisted single-point diamond turning (ILAT) on SiCp/Al metal matrix composites (MMCs), renowned for their exceptional mechanical properties and difficult-to-cut nature. The surface and subsurface response to the in-situ laser assistance under a small uncut chip thickness (UCT) is investigated. The results demonstrate that appropriate laser energy can reduce subsurface crystal defects while maintaining surface quality during machining. As the laser power increases, the surface damage pattern shifts from cut-through to fracture, eventually leading to severe matrix deformation. Slight compressive stress is observed on the Al phase of surfaces machined with either conventional single-point diamond turning (SPDT) or ILAT. Al crystals near the machined surface and SiC particles in the SPDT sample exhibit a notable accumulation of dislocations. Laser assistance is beneficial for mitigating dislocations and improving the crystalline integrity of Al grains, while Al grains close to the machined surface in both SPDT and ILAT samples present comparable amounts of stacking faults. The findings enhance the understanding of surface and subsurface generation of SiCp/Al composites in ILAT, providing a reference for the application of ILAT on other MMCs.

Diamond machining of additively manufactured Ti6Al4V ELI: Newer mode of material removal challenging the current simulation tools

Single point diamond machining (SPDM) produces smooth machined surfaces that other production methods cannot match. While the mechanics of machining of cast alloys with SPDM is well-explored, the realm of SPDM for additively manufactured parts remains largely uncharted. This work reveals new insights into the surface generation process of an additively manufactured titanium alloy, specifically, a Ti6Al4V Extra Low Interstitials (ELI) alloy workpiece. Our examination of the chip morphology unveiled a distinct mode of chip removal, previously unrecorded in existing literature. During SPDM of additively made Ti6Al4V ELI workpiece, identification of numerous pores and discontinuities in the chips flowing on the tool rake face, indicating periodic intermittent cracking during the material's plastic flow was seen. To examine this phenomenon, a finite element analysis (FEA) model was developed. While the FEA model can well explain the machining mechanics and chip morphology of SPDM of cast Ti6Al4V ELI reported in the literature, it failed to describe the chip morphology that are obtained during machining of additively made workpiece in this work. This disparity underscores the need for innovative simulation approaches tailored for additively manufactured components. The experimental observations in this study highlight a unique form of chip formation in contrast to conventional Ti6Al4V alloy machining processes. At lower feeds, there was a presence of short, discontinuous chip formation with tearing at the outer periphery. Conversely, at higher feeds, a long, continuous ribbon-like chip formation was observed. In addition, some typical additive manufacturing defects appear on the machined surface and chips. Through optimisation of the SPDT parameters, a surface roughness (Ra) value of about 11.8 nm was achieved on additively manufactured Ti6Al4V ELI workpiece. This work provides a fresh perspective on the mechanics of SPDM for additively manufactured components, offering a stepping stone for subsequent studies.

Fabrication of the optical lens on single-crystal germanium surfaces using the laser-assisted diamond turning

Single-crystal germanium, as an excellent infrared optical material, has been widely applied in X-ray monochromators, night vision systems, and gamma radiation detectors. However, how to obtain high-quality optical lenses on their surfaces still faces challenges due to their hard and brittle properties. To this end, this paper proposes the in situ laser-assisted diamond turning (ILADT) process, which is the combination of a laser heating technique and a single-point diamond turning process. The in situ laser heating technique is employed to enhance the surface quality of the workpiece material, while the single-point diamond turning process is utilized to fabricate optical lenses. Experimental results showed that optical lenses with high surface quality were successfully machined. The profile error is 0.135 μm, indicating the high machining accuracy. The surface roughness Sa of the aspheric lens is 0.909 nm, indicating the high machining quality achieved by the proposed ILADT process. Therefore, this study provides an effective approach for producing high-quality optical lenses on single-crystal germanium surfaces, which holds great promise for future applications in the manufacturing of optical lenses with exceptional quality.

Excellent strength-ductility synergy of Cu-Al alloy with a gradient nanograined-nanotwinned surface layer

Gradient nanostructured (GNS) metallic materials have shown significant potential in achieving excellent mechanical properties. However, the underlying strengthening mechanisms resulting from plastically inhomogeneous deformation in GNS materials, particularly those involving nanotwinned structures, remain inadequately understood. In this study, a gradient nanograined-nanotwinned (GNNT) surface layer was generated on a Cu-Al alloy using the severe plastic deformation technique known as single-point diamond turning. Uniaxial tensile and localized micropillar compression tests were conducted to compare the mechanical properties of GNNT samples with conventional gradient nanograined (GNG) and uniform coarse-grained (CG) Cu/Cu-Al counterparts. The results revealed that the GNNT samples exhibit excellent strength-ductility synergy, with a yield strength of approximately 329 MPa, tensile strength of around 477 MPa, and uniform ductility of about 48 %, thereby demonstrating remarkable strain hardening capacity and mechanical stability. These characteristics are further supported by the observed strong back stress effect, well-preserved mobile dislocation density, and effective suppression of grain coarsening in the GNNT surface layer. In contrast to the evident mechanically induced grain coarsening through grain boundary (GB) migration in the GNG surface layer, grain coarsening through twin boundary (TB) migration in GNNT surface layers is effectively inhibited by Lomer-Cottrell (L-C) locks formed by TB-stacking fault and TB-TB intersections, resulting in significantly enhanced structural stability. Furthermore, the L-C locks also extensively contribute to the high density of mobile dislocations observed in the GNNT samples. These findings provide valuable insights into the optimization of GNS structures for achieving excellent strength-ductility synergy in metallic materials.

High precision polishing of aluminum alloy mirrors through a combination of magnetorheological finishing and chemical mechanical polishing

After the aluminum alloy mirror machined by single point diamond turning (SPDT), the residual tool marks and surface accuracy of the aluminum alloy mirror cannot meet the requirements of visible or ultraviolet light system. In this study, a processing method combining magnetorheological finishing (MRF) and chemical mechanical polishing (CMP) is proposed to realize the polishing of aluminum alloy mirrors with high efficiency, high precision and high-quality. Firstly, the properties and composition of passivation layer after MRF were analyzed and the polishing performance of acidic, neutral and alkaline alumina polishing fluid on passivation layer were investigated based on the computer numerical control (CNC) polishing equipment. Based on the experimental results, a new acidic nano-silica polishing fluid which is suitable for the efficient and high-quality removal of passivation layers on aluminum alloy surfaces was developed. Finally, a combined approach of MRF-CMP was used to the directly polishing of a rapidly solidified aluminum mirror (RSA-6061) with a diameter of 100 mm after SPDT. With two iterative of MRF-CMP polishing in 220 minutes, the surface accuracy of the aluminum alloy mirror was improved from 0.1λ (λ=632.8 nm) to 0.024λ, and the surface roughness (Ra) decreased from 3.6 nm to 1.38 nm. The experiment results manifest that high precision, and high-quality aluminum alloy mirror can be achieved by MRF-CMP method with the new developed acid nano-silica polishing fluid and suitable MR polishing fluid. The research results will provide a new strategy for ultra-precision direct polishing of aluminum alloy mirrors and will also give the important technical support for the extensive use of aluminum alloy mirror in visible light and ultraviolet optical systems.

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

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).

Advancement of Analytical Model for Hydrophobic Rectangular Pillared Array on Al-Surface and Its Experimental Validation

AbstractOver the past few decades, self-cleaning surfaces have been significantly investigated due to their commercial applications in various fields. However, the researchers are still lagging in developing better mathematical models and fabricating hydrophobic surfaces for direct espousal in industry. In this study, a force-balanced system-based mathematical model is modified for a rectangular pillared array-based micro-structure and MATLAB simulations were used to validate it theoretically. The same pattern was developed on Al-surface using a single-point diamond turning (SPDT) machine experimentally. The experimental results were validated using coherence correlation interferometry (CCI), optical microscopy, drop shape analyser (DSA), and field emission scanning electron microscopy (FESEM). The experimentally estimated and theoretically predicted contact angles of the rectangular pillared array are found in close agreement. Further, the advancement in mathematical models and models-based surface manufacturing strategies can boost the research in this domain to develop robust self-cleaning hydrophobic surfaces.

ADVANCES IN ULTRAPRECISION DIAMOND TURNING: TECHNIQUES, APPLICATIONS, AND FUTURE TRENDS

Advances in ultraprecision diamond turning have revolutionized manufacturing processes across various industries, offering unparalleled precision and surface quality in the fabrication of optical components, microfluidic devices, and advanced mechanical parts. This review delves into the techniques, applications, and future trends in ultraprecision diamond turning, highlighting recent advancements and potential trajectories. Techniques in ultraprecision diamond turning have evolved significantly, driven by innovations in machine design, tooling materials, and control systems. Diamond turning machines equipped with ultra-stiff structures, high-speed spindles, and advanced feedback mechanisms enable sub-nanometer level accuracy and surface finishes down to Angstrom levels. Additionally, advancements in single-point diamond turning (SPDT), fast tool servo (FTS), and deterministic microgrinding (DMG) techniques further enhance the versatility and precision of the process. Applications of ultraprecision diamond turning span a wide range of industries, including aerospace, automotive, biomedical, and telecommunications. In optics manufacturing, diamond turning facilitates the production of aspheric lenses, freeform optics, and diffractive optical elements with unprecedented accuracy, contributing to the development of high-performance imaging systems and laser applications. Moreover, in the biomedical field, diamond-turned microfluidic devices enable precise control over fluid flow and particle manipulation, empowering advancements in drug delivery systems and lab-on-a-chip technologies. Future trends in ultraprecision diamond turning are poised to address challenges related to scalability, multi-material processing, and in-situ metrology. Integration of adaptive control algorithms and machine learning techniques promises enhanced process stability and predictive maintenance, optimizing productivity and reducing downtime. Furthermore, the development of hybrid manufacturing approaches, combining diamond turning with additive manufacturing or laser processing, offers novel avenues for fabricating complex, multi-functional components with improved efficiency and cost-effectiveness. The ongoing advancements in ultraprecision diamond turning techniques, coupled with diverse applications across industries, underscore its pivotal role in advancing manufacturing capabilities. Anticipated future trends hold promise for further expanding the scope and impact of this technology, driving innovation and pushing the boundaries of precision engineering.&#x0D; Keywords: Ultraprecision, Diamond, Turning, Technique, Review.

Research on Image Mapping Spectrometer Based on Ultra-Thin Glass Layered Mapping.

The imaging quality of the Mapping Imaging Spectrometer (IMS) is crucial for spectral identification and detection performance. In IMS, the image mapper significantly influences the imaging quality. Traditional image mappers utilize a single-point diamond machining process. This process leads to inevitable edge eating phenomena that further results in noticeable deficiencies in imaging, impacting spectral detection performance. Therefore, we propose a manufacturing process for the image mapper based on ultra-thin layered glass. This process involves precision polishing of ultra-thin glass with two-dimensional angles, systematically assembling it into an image mapper. The surface roughness after coating is generally superior to 10 nm, with a maximum angle deviation of less than 3'. This results in high mapping quality. Subsequently, a principle verification experimental system was established to conduct imaging tests on real targets. The reconstructed spectrum demonstrates excellent alignment with the results obtained from the Computed Tomography Imaging Spectrometer (CTIS). We thereby validate that this approach effectively resolves the issues associated with edge eating (caused by traditional single-point diamond machining), and leads to improved imaging quality. Also when compared to other techniques (like two-photon polymerization (2PP)), this process demonstrates notable advantages such as simplicity, efficiency, low processing costs, high fault tolerance, and stability, showcasing its potential for practical applications.