Numerical controlled polishing program, continued forced wear and part correction experiments

This abstract reports the near completion of the first phase of this program. It is the aim of this program to provide the operator of a N/C diamond turning machine or N/C grinding machine (jig grinder) with the wear characteristics necessary to achieve uniform material removal. The second phase of this program addresses a different problem, although solving this problem is highly dependent on the results of the first phase. Diamond turned, or any lathe turned surface, exhibits regular tool marks due to the tool passing over the surface being cut. Changes in depth of cut, feed rate and work rpm will change the character of these grooves, but will not eliminate them. Optical surfaces produced by this process exhibit increased scattering as the light wavelength decreases limiting their use; at least for optical purposes, to IR and some visible applications. Utilizing wear information gathered in the first part of this program we will attempt to reduce these residual tool marks by polishing. The polishing of diamond turned surfaces is not new. Diamond turned metal surfaces, especially in electroless nickel and high phosphorus nickel electroplate have been polished to improve their scatter characteristics. What we believe is unique is the use of a spherical wheel, rotating on axis and being moved over the part in a prescribed manner by numerical control. Over the past year we have made some major changes in our polishing methods and procedures. We have listed below these changes, as a refresher for the reader as to our previous procedures. These changes will be addressed in the body of the text.