Diamond Tool Wear in the Ultra-Precision Cutting of Large Electroless Nickel Coated Molding Dies

Akira Shinozaki; Yoshiharu Namba

doi:10.20965/ijat.2011.p0283

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IJAT Vol.5 No.3 pp. 283-288

doi: 10.20965/ijat.2011.p0283

(2011)

Paper:

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Diamond Tool Wear in the Ultra-Precision Cutting of Large Electroless Nickel Coated Molding Dies

Akira Shinozaki and Yoshiharu Namba

Chubu University, 1200 Matsumoto-cho, Kasugai-city, Aichi 487-8501, Japan

Received:

January 27, 2011

Accepted:

February 27, 2011

Published:

May 5, 2011

Keywords:

ultra-precision cutting, electroless nickel molding die, diamond tool, tool wear, on-machine measurement

Abstract

In recent years, in a field of space science, large and high precision aspherical molding dies which are used to make aspherical thin foil mirrors for the hard Xray telescope are needed. Therefore to establish the ultra-precision cutting method for these dies is overly expected. In the actual manufacturing, the largemolding die is required to have both high accurate shape accuracy and very small surface roughness as the finished product. To machine the large molding die which has these high accuracies, we should know factors to cause various errors such as shape error and surface roughness and so on. Because it is necessary to machine the large molding die by using NC machining system that automatically corrects shape error finally. Especially, the tool wear of diamond tool is one of the big factors that influences shape error and surface roughness, so it needs to correct the amount of tool wear while ultra-precision cutting of large molding dies. From these points of view, in this research, a tool wear of diamond tool which is used in the ultra-precision cutting of large electroless nickel coated molding dies is considered with an on-machine measurement and observation system.

Cite this article as:

A. Shinozaki and Y. Namba, “Diamond Tool Wear in the Ultra-Precision Cutting of Large Electroless Nickel Coated Molding Dies,” Int. J. Automation Technol., Vol.5 No.3, pp. 283-288, 2011.

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References

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[2] G. S. Lodha, K. Yamashita, T. Suzuki, I. Hatsukade, K. Tamura, T. Ishigami, S. Takahama, and Y. Namba, “Platinum/carbon multilayer reflectors for soft-x-ray optics,” Applied Optics, Vol.33 No.25, pp. 5869-5874, 1994.
[3] Y. Namba, G. Cao, A. Shinozaki, H. Kunieda, Y. Ogasaka, and K. Yamashita, “Fabrication of Pt/C multilayer-coated thin foil mirrors for hard X-ray telescope loaded in ASTRO-H satellite,” Annals of ASPE, Vol.47, pp. 176-179, 2009.
[4] S. K. Chon, Y. Namba, and K. H. Yoon, “Precision machining of electroless nickel mandrel and fabrication of replicated mirrors for a soft X-ray microscope,” Int. conf. of LEM 21^st century, pp. 1047-1050, 2005.
[5] K. S. Chon and Y. Namba, “Single-point diamond turning of electroless nickel for flat X-ray mirror,” J. of mechanical science and technology, Vol.24, No.8, pp. 1603-1609, 2010.
[6] J. Yan, T. Oowada, T. Zhou, and T. Kuriyagawa, “Precision machining of microstructures on electroless-plated NiP surface formolding glass components,” J. of materials processing Technology, Vol.209, pp. 4802-4808, 2009.
[7] E. Brinksmeier and R. Gläbe, “Basic studies on the wear behavior of modified and coated diamond tools for precision machining of ferrous materials,” Annals of ICPE, pp. 174-178, 2001.
[8] M. Shi, B. Lane, C. B. Mooney, T. A. Dow, and R. O. Scattergood, “Diamond tool wear measurement by electron-beam induced deposition,” Precision engineering, Vol.34, No.4, pp. 718-721, 2010.
[9] W. Gao, M. Tano, S. Sato, and S. Kiyono, “On-macnine measurement of a cylindrical surface with sinusoidal micro-structures by an optical slope sensor,” Precision engineering, Vol.30, No.3, pp. 274-279, 2006.
[10] Z. Q. Yin and S. Y. Li, “High accuracy error separation technique for on-machine measurement straightness,” Precision engineering, Vol.30, No.2, pp. 192-200, 2006.
[11] C. Evans andM. Holmes, “Metrology and calibraion of a long travel stage,” Annals of the CIRP, Vol.54, No.1, pp. 495-498, 2005.
[12] W. Gao, S. Dejima, Y. Shimizu, and S. Kiyono, “Precision measurement of two Axis positionsand tilt motions using a surface encoder,” Annals of CIRP, Vol.52, No.1, pp. 435-438, 2003.
[13] W. Gao, M. Tano, T. Araki, S. Kiyono, and C. H. Park, “Measurement and compensation of error motions of a diamond turning machine,” Precision engineering, Vol.31, No.3, pp. 310-316, 2007.

This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

[1] [1] Y. Ogasaka, H. Kunieda, T. Miyazawa, P. Serlemitsos, et al., “The NeXT x-ray telescope system: status update,” Proc. of SPIE., Vol.70110, pp. 1-8, 2008.

[2] [2] G. S. Lodha, K. Yamashita, T. Suzuki, I. Hatsukade, K. Tamura, T. Ishigami, S. Takahama, and Y. Namba, “Platinum/carbon multilayer reflectors for soft-x-ray optics,” Applied Optics, Vol.33 No.25, pp. 5869-5874, 1994.

[3] [3] Y. Namba, G. Cao, A. Shinozaki, H. Kunieda, Y. Ogasaka, and K. Yamashita, “Fabrication of Pt/C multilayer-coated thin foil mirrors for hard X-ray telescope loaded in ASTRO-H satellite,” Annals of ASPE, Vol.47, pp. 176-179, 2009.

[4] [4] S. K. Chon, Y. Namba, and K. H. Yoon, “Precision machining of electroless nickel mandrel and fabrication of replicated mirrors for a soft X-ray microscope,” Int. conf. of LEM 21^st century, pp. 1047-1050, 2005.

[5] [5] K. S. Chon and Y. Namba, “Single-point diamond turning of electroless nickel for flat X-ray mirror,” J. of mechanical science and technology, Vol.24, No.8, pp. 1603-1609, 2010.

[6] [6] J. Yan, T. Oowada, T. Zhou, and T. Kuriyagawa, “Precision machining of microstructures on electroless-plated NiP surface formolding glass components,” J. of materials processing Technology, Vol.209, pp. 4802-4808, 2009.

[7] [7] E. Brinksmeier and R. Gläbe, “Basic studies on the wear behavior of modified and coated diamond tools for precision machining of ferrous materials,” Annals of ICPE, pp. 174-178, 2001.

[8] [8] M. Shi, B. Lane, C. B. Mooney, T. A. Dow, and R. O. Scattergood, “Diamond tool wear measurement by electron-beam induced deposition,” Precision engineering, Vol.34, No.4, pp. 718-721, 2010.

[9] [9] W. Gao, M. Tano, S. Sato, and S. Kiyono, “On-macnine measurement of a cylindrical surface with sinusoidal micro-structures by an optical slope sensor,” Precision engineering, Vol.30, No.3, pp. 274-279, 2006.

[10] [10] Z. Q. Yin and S. Y. Li, “High accuracy error separation technique for on-machine measurement straightness,” Precision engineering, Vol.30, No.2, pp. 192-200, 2006.

[11] [11] C. Evans andM. Holmes, “Metrology and calibraion of a long travel stage,” Annals of the CIRP, Vol.54, No.1, pp. 495-498, 2005.

[12] [12] W. Gao, S. Dejima, Y. Shimizu, and S. Kiyono, “Precision measurement of two Axis positionsand tilt motions using a surface encoder,” Annals of CIRP, Vol.52, No.1, pp. 435-438, 2003.

[13] [13] W. Gao, M. Tano, T. Araki, S. Kiyono, and C. H. Park, “Measurement and compensation of error motions of a diamond turning machine,” Precision engineering, Vol.31, No.3, pp. 310-316, 2007.