Goal:
Demonstrate the capability and present key metrology results and process data for a non-axisymmetric D-Pocket used as a registering feature in lens molds, for more accurate indexing
Process Parameters:
• XZ High speed diamond turning for lens
• XZC Diamond turning for D-Pocket
• Single machine setup
Part Details:
• Material: 12.5 mm Electroless Nickel pin
• Lens diameter: 4 mm
• Pocket diameter: 5.431 6 0.001 mm
— Concentricity to lens: 6 0.001 mm
• D-Pocket parameters:
— Flat offset: 2.55 mm (sag: 0.165 mm)
— Corner radii: 0.5 mm
— Depth: 0.6 mm 6 0.001 mm
Setup Photo
Part Photo
Machining Details:
• Lens spindle speed: 3,000 RPM
• D-Pocket parameters:
— Spindle speed: 85 RPM
— Depth of cut: 10 µm
— Feed per rev: 10 µm
— Cycle time: 20 minutes
• Coolant: Odorless mineral spirits (OMS)
Tool Details:
• K&Y single point diamond tool with 20˚ clearance
• Radius: 53 µm
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