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Diamond turning of aspheric steel molds for optics replication

: Klocke, F.; Dambon, O.; Bulla, B.


Maher, M.A. ; Society of Photo-Optical Instrumentation Engineers -SPIE-, Bellingham/Wash.:
Micromachining and microfabrication process technology XV : 26 January 2010, San Francisco, California, United States
Bellingham, WA: SPIE, 2010 (Proceedings of SPIE 7590)
ISBN: 978-0-8194-7986-0
Paper 75900B
Conference "Micromachining and Microfabrication Process Technology" <15, 2010, San Francisco/Calif.>
Photonics West Conference <2010, San Franciso/Calif.>
Conference Paper
Fraunhofer IPT ()

Diamond turning of steel parts is conventionally not possible due to the high tool wear. However this process would enable several different application with high economical innovative potential. One technology that enables the direct manufacturing of steel components with monocrystalline diamond is the ultrasonic assisted diamond turning process. This technology has been investigated over years within the Fraunhofer IPT and has proven its potential. Surface roughness in the range of Ra = 5 nm are reached and the diamond wear is reduced by a factor 100 or higher. Up to now this process has been investigated in lab conditions manufacturing only plane surfaces. In order to prove its industrial suitability, two relevant aspherical shapes, convex and concave respectively, have been defined and manufactured. The reached form accuracies and surface roughness values will be described in this paper.