Ultra-Precise Single-Point Diamond Turning Process and Its Low-Cost Alternative Methods

Single-point diamond turning (SPDT) is an ultra-precision subtractive material removal process to achieve optical-finish surfaces almost on any material. Due to this capability to produce nano-level surface finish, it has become an important advanced manufacturing process for optics, semiconductors, biomedical, defense and aerospace sectors. However, due to its initial setup cost, its popularity and uses have been suppressed in many regions. As it is a nanoscale regime machining process, size effect has a major influence along with effective rake angle, tool wear, crystallographic orientation, ploughing, rubbing, burnishing, build-up edge, tool vibration, material swelling and elastic recovery. All these factors need to be studied to understand in order to improve the outcome of the process. Numerical simulation is one of the low-cost alternative methods to study the process and its influencing factors on product quality and process efficiency. These techniques can provide insight into the effects of cutting process that are often difficult see through physical experiments. Studies showed that the methods helped the researchers in understanding the insight of process, physics and origins of chip formations, microstructural behaviour during plastic deformation. Thus, it is ascertained that these alternatives methods if effectively designed may help to cut down the (a) operating and metrological cost and time, (b) predict the outcome of the processes and (c) optimize the process parameters without carrying out costly and tiresome experiments. The approach is found to be simple and economical and a possible substitute for costly, tedious and time-consuming physical experiments.