Goal:
Demonstrate the capability to machine optical grade micro-grooves on a freeform surface with a groove depth variability under 3 µm.
Process:
Flycut grooves on a gullwing freeform surface using a Freefrom MGG® (micro-groove generator) with HS75FF spindle. The fully contouring vertical axis of the Freeform MGG follows the gullwing surface resulting in groove depth variability under 3 µm.
Part Details:
Material: Bronze
Diameter: 164.0 mm
Vertical departure from flat surface: 2 mm
Part Photo
Part photo under magnification on
Taylor Hobson Form Talysurf
Groove Details:
Depth: 50 µm
Pitch: 350 µm
Number: 115 – 90 degree intersection sets
Groove area: 40 mm (intersecting groove area 40 mm x 40 mm)
Set up
In process
Process Details:
Tool: 0.38 µm radius diamond tool Spindle speed: 2000 rpm
Feed rate: 100.0 mm/min
Flycutter swing radius: 87.96 mm
Results:
Total groove depth variability: < 3 µm
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