Goal:
Demonstrate the capability to machine 45º helical grooves on a 1.4 meter drum with no visible seam between the first and last groove.
Process:
XZC diamond turning on a DRL1600 with a 90º included angle tool mounted at a 45º angle. Tight temperature control is used over the long cutting time to insure that there is no visible seam between the first and last groove.
Part Details:
Material: Copper-plated steel drum
Length: 1400 mm
Diameter: 270 mm
Weight: 350 kg
Optical zones: 1100 mm
45° Tool Setting
Machine Details:
Spindle type: oil bearing
Slide type: oil bearing, water cooled, linear motor driven
Temperature control: Praecis® temperature control
Process Details:
Tool angle: 90º included angle
Spindle speed: 12 rpm
Z axis feed rate: 10 m/min
Pitch: 50 µm
Depth: 25 µm, cut in one pass
Machine time: ~ 50 hrs
Cutting Process
Inspection
Results:
• Pitch variability: < 0.5 µm
• No visible seam between first and last groove
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