EFFECT OF TOOL WEAR AND TOOL SETTING ON PROFILE ACCURACY OF DIAMOND-TURNED NONFERROUS COMPONENTS

Diamond turning technology has gained great importance in high-precision optical component fabrication. The quality of machined optical surfaces is mainly affected by the machine tool's accuracy, cutting tool's quality, and dynamic machining effects. This study investigated the effects of cutting tool conditions and tool set-up error on the surface distortion. Controlled cutting tests were performed on a two-axis diamond turning machine. Spherical mirrors with preset tool offset values and tool height values were turned. The relationship among machined form accuracy, tool offset, and tool height was investigated based on experimental and analytical results. The influence of tool wear on machined surface quality was studied. Factors governing uneven wear along the cutting edge in contour machining were analyzed. A spherical surface with a form accuracy better than λ/10 was produced. Methods for minimizing the effect of tool wear are also discussed.