Special issue - Ultra-precision machining
At a Glance
Section titled âAt a Glanceâ| Metadata | Details |
|---|---|
| Publication Date | 2017-03-01 |
| Journal | Frontiers of Mechanical Engineering |
| Authors | Zhuangde Jiang, Dongming Guo |
| Institutions | Dalian University of Technology, Xiâan Jiaotong University |
| Citations | 6 |
| Analysis | Full AI Review Included |
Technical Documentation & Analysis: Ultra-Precision Machining
Section titled âTechnical Documentation & Analysis: Ultra-Precision MachiningâThis analysis connects the critical material requirements identified in the âSpecial issue: Ultra-precision machiningâ editorial to the advanced MPCVD diamond solutions offered by 6CCVD. The research highlights the indispensable role of high-quality diamond tooling in achieving sub-micron precision and ultra-smooth surfaces (Ra < 1nm) across diverse applications, including optics, consumer electronics, and high-power laser systems.
Executive Summary
Section titled âExecutive Summaryâ- Core Value Proposition: The advancement of ultra-precision machining (UPM), including diamond machining and micro-cutting, is fundamentally dependent on the quality and customization of CVD diamond tool materials.
- Material Requirement: Achieving the required low surface/subsurface damage in hard and brittle materials (optical glass, ceramics, KDP crystals) necessitates high-purity, low-defect Single Crystal Diamond (SCD) tool blanks.
- 6CCVD Solution: 6CCVD specializes in providing Optical Grade SCD plates and high-toughness Polycrystalline Diamond (PCD) wafers, custom-engineered for the fabrication of SPDT tools, fly-cutting inserts, and micro-milling components.
- Precision Capability: We offer SCD polishing down to Ra < 1nm, directly supporting the manufacture of ultra-smooth molds required for Precision Glass Molding (PGM) and polymer optics.
- Customization: 6CCVD supports the development of specialized micro-tools by offering custom dimensions (up to 125mm) and integrated metalization services (Au, Ti, Pt, etc.) for secure tool bonding.
- Strategic Application: Our materials are essential for researchers and engineers focused on âManufacturing 3.0â principles, where atomic-scale precision dictates product quality and performance.
Technical Specifications
Section titled âTechnical SpecificationsâThe editorial emphasizes performance metrics achievable only through the use of high-quality diamond tooling. The table below outlines the implied material requirements and the corresponding capabilities offered by 6CCVD.
| Parameter | Value | Unit | Context |
|---|---|---|---|
| Target Surface Roughness (UPM) | Ra < 1 | nm | Required for optical components and PGM molds (achieved via SCD tooling). |
| Machining Scale | Micro- to Nano- | N/A | Focus on micro-cutting, nano-patterning, and micro-end milling. |
| Required Tool Material Hardness | 10 | Mohs | Diamond (SCD/PCD) is the only material capable of ultra-precision machining hard/brittle materials. |
| 6CCVD SCD Thickness Range | 0.1 - 500 | ”m | Custom tool blanks for SPDT and micro-tool fabrication. |
| 6CCVD PCD Wafer Diameter | Up to 125 | mm | Large-area substrates for robust milling inserts and grinding wheels. |
| Achieved Product Accuracy | G3-level | N/A | Achieved for ceramic balls using ultra-precision methods (requires diamond abrasives/tools). |
| Polishing Capability (SCD) | Ra < 1 | nm | Guaranteed surface finish for critical optical tool applications. |
Key Methodologies
Section titled âKey MethodologiesâThe research papers reviewed in this special issue utilize advanced manufacturing techniques that rely heavily on the mechanical, thermal, and chemical properties of CVD diamond materials.
- Diamond Machining (Single Point Diamond Turning / Fly-cutting):
- Used extensively for achieving ultra-smooth surfaces on optical glass, polymers, and soft-brittle crystals (KDP).
- Requires defect-free Single Crystal Diamond (SCD) to maintain a sharp, durable cutting edge and minimize subsurface damage.
- Precision Glass Molding (PGM) and Polymer Optics Molding:
- Molds must be fabricated with extreme precision and ultra-low roughness, typically achieved by diamond machining the mold material (e.g., tungsten carbide).
- The quality of the diamond tool directly determines the quality of the final optical microstructure.
- Micro-cutting and Micro-milling:
- Involves designing and manufacturing specialized micro-tools (e.g., micro-ball-end mills) capable of machining complex geometries in hard materials (e.g., Al6061-T6, ceramics).
- These tools often utilize PCD inserts or diamond coatings for enhanced wear resistance.
- Lapping and Figuring:
- Processes used for final surface refinement, often employing diamond abrasives (powder or slurry) derived from CVD diamond material.
- Ultrasonic-assisted Machining:
- Used to address limitations of conventional diamond machining when fabricating micro/nano-textured surfaces, requiring highly durable diamond tools capable of withstanding high-frequency vibration.
6CCVD Solutions & Capabilities
Section titled â6CCVD Solutions & Capabilitiesâ6CCVD is uniquely positioned to supply the foundational diamond materials necessary to replicate and advance the ultra-precision machining research detailed in this special issue.
Applicable Materials
Section titled âApplicable Materialsâ| Application Requirement | 6CCVD Material Solution | Key Benefit |
|---|---|---|
| Single Point Diamond Turning (SPDT) Tools | Optical Grade Single Crystal Diamond (SCD) | Highest purity and lowest defect density, ensuring tool edges capable of achieving Ra < 1nm on optical components and PGM molds. |
| Micro-Milling Inserts & Grinding Wheels | High-Toughness Polycrystalline Diamond (PCD) | Superior wear resistance and thermal stability for robust micro-cutting of ceramics and metals (e.g., Al6061-T6). Available in large formats up to 125mm. |
| Electrochemical/Advanced Machining | Boron-Doped Diamond (BDD) | Available for researchers exploring micro-electrical-discharge machining (micro-EDM) or electrochemical diamond applications. |
Customization Potential
Section titled âCustomization PotentialâTo meet the stringent requirements of UPM research, 6CCVD offers extensive customization capabilities:
- Custom Dimensions and Geometry: We provide SCD and PCD plates/wafers up to 125mm in diameter, allowing for the fabrication of large-scale tool inserts or specialized grinding wheels referenced in the micro-machining papers.
- Precision Thickness Control: SCD and PCD materials are available from 0.1”m to 500”m thickness, enabling precise material selection for specific tool geometries (e.g., thin SCD for micro-tool tips).
- Ultra-Smooth Polishing: We guarantee Ra < 1nm polishing on SCD and Ra < 5nm on inch-size PCD, critical for manufacturing the ultra-smooth molds required for PGM.
- Integrated Metalization: For secure bonding of diamond tool blanks into high-speed fly-cutting or milling holders, 6CCVD offers in-house deposition of standard metal stacks, including Ti/Pt/Au, W, Pd, and Cu.
Engineering Support
Section titled âEngineering Supportâ6CCVDâs in-house team of PhD material scientists and engineers provides authoritative support for complex diamond applications. We can assist researchers in optimizing material selection based on the target workpiece (e.g., choosing the optimal SCD orientation for fly-cutting KDP crystals) and required surface finish. Our expertise ensures that the diamond material chosen is perfectly matched to the demands of Ultra-Precision Machining (UPM) and Precision Glass Molding (PGM) projects.
For custom specifications or material consultation, visit 6ccvd.com or contact our engineering team directly.