A theoretical and experimental investigation into tool setting induced form error in diamond turning of micro-lens array

Guo, Pan; Li, Zhen; Zhang, Xiong; Zhang, Shaojian

doi:10.1007/s00170-022-10643-z

Cited by 7 publications

(4 citation statements)

References 27 publications

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“…Zhang et al (Zhang et al, 2020) used a femtosecond laser to fabricate the MLA on ZnSe; results show the root-mean-square deviation between the measured cross-sectional profile and the ideal parabola was less than 70nm. Guo et al (Guo et al, 2022) fabricated MLA on isotropic oxygen-free copper using a two-step tool setting method in diamond turning. The surface topography measurement was conducted on a white light interferometer, and an error of 65 nm has been obtained.…”

Section: Resultsmentioning

confidence: 99%

Optical design and fabrication of zinc selenide microlens array with extended depth of focus for biomedical imaging

Khatri

Berwal

Manjunath

et al. 2023

Nanofab

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Optical coherence tomography is a well-known technique for the optical imaging biological tissues. However, the depth scanning range of high-resolution optical coherence tomography is restricted by its depth of focus. In this study, a Zinc Selenide (ZnSe) Microlens Array (MLA) is employed to overcome the depth-of-focus limitation of optical coherence tomography. The ZnSe material with a low Abbe number and high chromatic dispersion extends the depth of focus with transverse resolution. The ZnSe MLA focused the incident light (from visible to near-infrared (NIR) region) on multiple focal planes with the uniform distribution of light over a biological tissue. The MLA is designed using Zemax OpticStudio software and fabricated via a single-point diamond-turning based on Slow Tool Servo (STS) configuration. STS machining has the unique advantage of offering larger degrees of freedom with no additional baggage, thereby reducing the setup time. The experimental results show the effectiveness of the STS machining process in fabricating ZnSe MLA with desired accuracies. The characterization of fabricated MLA using Coherence Correlation Interferometry (CCI) depicts uniform lenslets with no structural and positional distortion, with a total error of 32 nm within the tolerance limit.

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Section: Resultsmentioning

confidence: 99%

Optical design and fabrication of zinc selenide microlens array with extended depth of focus for biomedical imaging

Khatri

Berwal

Manjunath

et al. 2023

Nanofab

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“…According to these authors, taking tool-workpiece compliance into account is essential for developing a more accurate model. Guo et al [22] explored the influence of tool setting on the form error in MLA (Micro Lens Array) manufacturing and proposed a novel two-step tool setting strategy for UPDT (Ultra-Precision Diamond Turning) in their research. Initially, they established a theoretical model to describe form errors in MLA resulting from tool setting inaccuracies.…”

Section: Introductionmentioning

confidence: 99%

Development of Theoretical and Numerical Framework for Selecting the Cutting Process Parameters for Turned Slender Parts

Ezugwu,

Fayomi,

Onifade

et al. 2023

JESA

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Metal cutting productivity or material removal rate is a constrained objective. Higher productivity, which is guaranteed by higher cutting process parameters (feed, speed, and depth of cut), is accompanied by higher constraining and unwanted factors like higher cutting forces, higher power demand, higher machine tool and workpiece deflections (in other words, form error), higher waste heat generation and coolant demand, faster tool wear rate, higher predisposition to periodic and regenerative chatter, compromised surface quality, etc. The research focused on the development of theoretical and numerical framework for selecting the cutting process parameters to enhance the productivity, integrity, and accuracy of turned slender parts. The method involved theoretical modelling that expresses material removal rate and form error in terms of cutting process parameters, workpiece flexibility parameters, workpiece geometrical parameters, and kinematic parameters. Cutting tests were carried out in validation of the arising theoretical and numerical results. Parametric studies were carried out using the developed computational model to understand the trend of accuracy and productivity with variation of cutting process parameter. As expected, the parametric study shows that flexibility of the slender workpiece reduced MRR. The results showed that deviation of predicted values of MRR from the desired values rises with rise of all the cutting process parameters; feed, depth of cut and spindle speed. The findings also indicate that as the feed rate and depth of cut increase, the variance between the predicted diameter and the target values also increases. However, there is a fluctuating pattern with a gradual decrease in variance as the spindle speed rises. Based on the results of the parametric studies, specified tolerance ranges could be met by choosing parameter sets that meet the specifications. If the numerical model relies on FEA, it might require extensive computational resources and expertise, limiting its practicality. Overcoming these limitations often involves continuous research and development efforts, incorporating real-world data, and improving the accuracy and adaptability of the framework for specific machining scenarios. The parametric study results can be used as a framework for the selection of cutting process parameter to enhance the productivity, integrity, and accuracy of turned slender parts.

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“…Ultra-precision machining (UPM) is one of the most advanced fabrication methods to create a high-quality surface with a sub-micrometric form accuracy and nanometric surface roughness [1]. In UPM, there are inevitably various errors that affect the surface quality of the machined components, such as geometric errors [2,3], tool errors [4,5], thermal errors [6,7], dynamic errors [8,9], etc. The geometric errors, as a crucial contributor of up to 40-70%, majorly affect the form accuracy of a machined surface [10].…”

Section: Introductionmentioning

confidence: 99%

A Theoretical and Experimental Identification with Featured Structures for Crucial Position-Independent Geometric Errors in Ultra-Precision Machining

Zhang,

Zhang

2023

Machines

Self Cite

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In ultra-precision machining (UPM), position-independent geometric errors (PIGEs), i.e., squareness errors, have a crucial impact upon the form accuracy of a machined surface. Accordingly, more research work has been conducted in PIGE identification, to improve the form accuracy. However, the general identification methods were developed without consideration of the specific squareness errors for crucial PIGEs under the form errors of the machining process. Therefore, a new method with featured structures was proposed, to identify crucial PIGEs in UPM. Firstly, a volumetric error model was developed for PIGEs, to discuss the relationship between squareness errors and their resulting machining form errors. Secondly, following the developed model, some featured structures have been proposed with their machining form errors, to significantly indicate crucial PIGEs. Finally, a series of UPM and measuring experiments were conducted for the featured structures, and then their machining form errors were measured and extracted with specific squareness errors for the identification of crucial PIGEs. The theoretical and experimental results revealed that the proposed method is simple and efficient with the featured structures to accurately identify crucial PIGEs in UPM. Significantly, the study offers a deep insight into high-quality fabrication in UPM.

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A theoretical and experimental investigation into tool setting induced form error in diamond turning of micro-lens array

Cited by 7 publications

References 27 publications

Optical design and fabrication of zinc selenide microlens array with extended depth of focus for biomedical imaging

Optical design and fabrication of zinc selenide microlens array with extended depth of focus for biomedical imaging

Development of Theoretical and Numerical Framework for Selecting the Cutting Process Parameters for Turned Slender Parts

A Theoretical and Experimental Identification with Featured Structures for Crucial Position-Independent Geometric Errors in Ultra-Precision Machining

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