A hybrid fabrication approach and profile error compensation for silicon aspheric optics

Sharma, Rohit; Mishra, Vinod; Khatri, Neha; Garg, Harshit; Karar, Vinod

doi:10.1177/0954405417733018

Cited by 9 publications

(5 citation statements)

References 25 publications

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“…The input parameters are also responsible for varying cutting forces and phase transformation. This may lead to fracture in optical components [19,20]. Several experimental results are reported, establishing the relationship between SSD and surface roughness of the optical components [21][22][23][24].…”

Section: Introductionmentioning

confidence: 89%

Effect of machining parameters on surface finish and subsurface damage for diamond-turned germanium

Sharma

Mishra

Garg

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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Germanium lenses are widely used in various scientific and technological applications mainly infrared optical components. The performance of these lenses depends upon the surface finish, which is challenging to achieve during ductile-regime machining. It is crucial to provide the optimum parameters to ensure the high-quality surface, without surface and subsurface damage. In the present work, an attempt has been made to analyse the effect of input machining parameters on surface finish and subsurface damage distribution, induced during the diamond turning. Taguchi's optimization has been performed to optimize the parameters affecting the performance and surface quality of fabricated components. Abbott-Firestone (A-F) curve is utilized to study the distribution of peaks and valleys on the machined surface. Additionally, chip morphology and machining forces are analysed to study the material removal behaviour at varying parameters. Further, indentations are performed on the best and worst combinations to examine the effect of parameters selection on surface cracks propagation. It is found that surface with a greater number of valleys leads to chipping during indentation. In this study, a surface roughness of 2.3 nm is achieved with minimum subsurface deformation.

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Section: Introductionmentioning

confidence: 89%

Effect of machining parameters on surface finish and subsurface damage for diamond-turned germanium

Sharma

Mishra

Garg

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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“…Moreover, the technique has played a crucial role in the advancements of drug delivery systems, particularly through the fabrication of diamond-turned microfluidics, which has enabled the realization of novel drug delivery systems (Zhou et al, 2018). Furthermore, ultraprecision diamond turning has significantly impacted aerospace and automotive applications by enabling the production of precision mechanical parts for aerospace components (Sharma et al, 2017;Balogun et al, 2024). In the automotive sector, the technique has been instrumental in the creation of optical elements for automotive sensors and lighting systems, showcasing its versatility and relevance in diverse industrial applications (Hou et al, 2019).…”

Section: Applications Of Ultraprecision Diamond Turningmentioning

confidence: 99%

Advances in Ultraprecision Diamond Turning: Techniques, Applications, and Future Trends

Adeniyi Kehinde Adeleke,

Danny Jose Portillo Montero,

Emmanuel Chigozie Ani

et al. 2024

Eng. sci. technol. j.

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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. Keywords: Ultraprecision, Diamond, Turning, Technique, Review.

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“…Modern telescope optical systems rely on the development of aspheric optical elements, and the precision surface is strongly linked to the quality of imaging [1][2][3]. The Ritchey-Chretien (R-C) optical system as a representative design presents some advantages in the reflective optical system.…”

Section: Introductionmentioning

confidence: 99%

The Fabrication of a High-Precision Rotational Symmetric Hyperboloid Mirror by Magnetron Sputtering with Film Thickness Correction

et al. 2022

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With the rapid development of optical systems, aspheric reflective optics have become more and more widely used because of their advantages in obtaining better imaging quality. Meanwhile, the optical systems have higher requirements in terms of the surface precision of their optical elements. In this study, we proposed an improved profile-coating method to realize a two-dimensional surface correction method on a rotational symmetric hyperboloid mirror. This method used an irregular mask based on a planetary motion magnetron sputtering system to control film thickness distribution. Moreover, film thickness calibration with a step test was carried out to reduce the processing error of the mask. An optical profiler was used in the step test to quantitatively characterize film thickness distribution and a tilt correction was introduced to correct the test error. As a result, an improvement in figure error in the radial direction of 17.7 nm Root Mean Square (RMS) was achieved. According to these optimization methods, the mask was trimmed for film deposition on the spherical surface. Measurement results from the interferometer show that the figure error of film was 16.23 nm RMS, demonstrating the effectiveness of the optimized method for fabricating a rotational symmetric hyperboloid mirror.

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A hybrid fabrication approach and profile error compensation for silicon aspheric optics

Cited by 9 publications

References 25 publications

Effect of machining parameters on surface finish and subsurface damage for diamond-turned germanium

Effect of machining parameters on surface finish and subsurface damage for diamond-turned germanium

Advances in Ultraprecision Diamond Turning: Techniques, Applications, and Future Trends

The Fabrication of a High-Precision Rotational Symmetric Hyperboloid Mirror by Magnetron Sputtering with Film Thickness Correction

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