Goal:
Utilizing laser assisted machining, demonstrate improved surface finish and cosmetic appearance by reducing visual haze and pullouts on ZnS.
Process:
Using a Nanoform® X, MicroLAM Optimus T+1 laser assisted machining device, and HS150 Spindle to diamond turn a ZnS asphere using XZ (2 axis) machining.
Part Details:
Material: Zinc Sulfide (ZnS)
Diameter: 88 mm
Best fit concave radius: 132 mm
Part photos under high intensity light
Without laser
With laser
Tool Details (proprietary MicroLAM diamond tool):
Radius: 0.5 mm
Sweep: 120°
Sweep used: 20°
Rake angle: -35°
Setup photos
Process Details:
Spindle speed: 5000 rpm
Feed rate: 5 mm/min
Feed per revolution: 1 µm/rev**
Coolant: Odorless Mineral Spirits (OMS)
** 2X typical feed per rev
Results (Metrology):
Without laser:
• Surface finish: 3.5 nm Ra
• Cosmetics: Visible color, haze, and pullouts under high intensity light
• Form accuracy: 0.30 µm PV
With laser:
• Surface finish: 1.0 nm Ra
• Cosmetics: No visible color, haze, and pullouts under high intensity light
• Form accuracy: 0.17 µm PV
Metrology:
Without laser
With laser
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