Experimental investigation for optical flatness in an aluminium alloy 6061 by single point diamond turning

• Main Author: Surya Prabhu Mohanasundaram.
• Other Authors: Sathyan Subbiah
• Format: Theses and Dissertations
• Language: English
• Published: 2013
• Subjects: DRNTU::Engineering::Mechanical engineering
• Online Access: http://hdl.handle.net/10356/55147
• Institution: Nanyang Technological University

Optically flat components are increasing in more demand, which is hard to manufacture with high precision and accuracy. Ultra precision (SPOT) Single Point Diamond Turning Machine is used for production of these components with high vibration isolation provided by means of epoxy granite base. Thus achieving accuracy less than or equal to 0.15 mirco-m and finish tolerance less than or equal to 5 om with such technique respectively. In this study, aluminium alloy 6061 of rectangular section 16x23mm is turned using single point, single crystal natural diamond tool of nose radius 0.5mm, using Precitech 4200 machine. Experiments are carried out by varying the cutting parameters such as depth of cut, feed rate, and rpm of the spindle for different experimental setup to determine the surface flatness, roughness, and waviness. Machining is undertaken with both the nose and side cutting edge of the tool, and results are compared to determine the flatness for achieving the surface roughness value between 0.5 - 0.6 fringes. On the basis of these experimental results, it is found that the side edge cutting of the tool provides the better flatness on the work piece surface than the nose edge cutting due to generation of the wiping effect phenomena by the tool. Surface measurements are made using Zygo Interferometer to determine the level of flatness. This study is of interest to companies such as QIOPTIC.