Ultraprecision Manufacturing

In this presentation, solutions for ultraprecision machining are presented with FANUC ROBONANO as a relevant example. Thus, the main features of the machine tool are described with the aim of understanding the key technologies that are required in order to finish functional surfaces with optical quality. Challenges and opportunities are discussed by showing a number of samples that are relevant to different industries and machining strategies. Finally, the workflow for the fabrication of a mould insert will be outlined, from machine set-up to quality inspection.

Zeeko has been making specialist 7 axis machines for polishing high precision freeform glass optics for 20 years. Such optics have a P-V measurement in tens of nanometers and a roughness Ra often ≤ 1nm. Over recent times the Company has developed new processes that include a ductile grinding process with tools that can operate on different platforms such as regular 3, 4 and 5 axis CNC millers and turning centres. Most recently these processes are being released as 6 axis industrial robot polishing cells. Applications involve parts as diverse as hip and knee joints, precision moulds for optical and near optical components, turbine blades and many others. Materials also vary from glass to steel, carbides, plastic, aluminium and many others. Additive manufactured parts in plastic and metal are a particular speciality.

The presentation will review the processes involved, briefly explore the science behind them, the software that enables them to be commercially applied and the capabilities being exploited in the market place. It will end by discussing some observations and comments on the ease of use of this truly automated polishing technology.

A fast, optical scattered light sensor for roughness, form and waviness is presented, which is characterized by its high precision and robustness. After a brief introduction to the basics of the scattered light method, applications from the areas of ultra-precision machining and fine milling are presented.

In this presentation, Menno Kalmann will show the challenges you encounter when polishing a diamond radius with controlled waviness. Within the optical market, there are many challenges you should take into consideration. Lenses are getting smaller, more precise, and more complex. The surface of a lens must be optical quality (mirror) and this can only be made with a diamond tool. The accuracy of the lens radius depends on the accuracy and deviation of the radius of the tool. Accuracy is a tolerance on radius. Deviation of the determined radius is Controlled Waviness.

The capability to produce surfaces in optical quality is of rising prominence in the manufacturing industry. The die and mold industry have to meet rising requirements with regard to the surface finish and geometric precision, to keep pace with technological advances in sectors such as illumination, optical sensors, and fiber technology. The precision of modern industrial machine tools approaches the UPM range, enabling the production of optical finishes straight off the machine.

Two sample processes for hardened steel and soft non-ferrous materials are presented. The process is discussed in its entirety, from tool selection, work-piece setup, machining strategies towards a practical cleaning solution as well as the correct measurement of the produced surfaces.

Conoptica is in the unique position of having more than ten years of experience in inline camera-based measurements of milling tools. The tools offer you a deep dive into the benefits, advantages and possibilities behind camera-based measurements.

Learn how camera-based measurements can give you more control of your milling tools, and thus,  more control over your process.  See the potential of camera-based measurement – and what lies in store for the near future.