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Proceedings Paper

Direct diamond turning of steel molds for optical replication
Author(s): Fritz Klocke; Olaf Dambon; Benjamin Bulla; Michael Heselhaus
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Paper Abstract

In this paper the most recent investigations in ultrasonic assisted diamond machining of hardened steel at the Fraunhofer IPT is presented. The goal of this technology is to unify the outrageous specifications of diamond machining process with steel material. The focus lies on the kinematic influence of the discrete frequencies 40 kHz and 60 kHz. Special interest is given to the reachable surface roughness depending on process parameters. The machined steel (1.2083, X40Cr14, STAVAX ESU) is a common mold die material for optical replication processes.Results of the accomplished investigations show the potential of the ultrasonic assisted process and recent developments. By increasing the frequency from 40 kHz to 60 kHz the overall process stability is increased. This makes the process less vulnerable towards feed rate variation or towards the variation of machined material hardness. Furthermore no tool wear is detected at high material removal rates or high cutting distances during component machining.

Paper Details

Date Published: 20 May 2009
PDF: 7 pages
Proc. SPIE 7282, 4th International Symposium on Advanced Optical Manufacturing and Testing Technologies: Advanced Optical Manufacturing Technologies, 728202 (20 May 2009); doi: 10.1117/12.830778
Show Author Affiliations
Fritz Klocke, Fraunhofer Institute for Production Technology (Germany)
Olaf Dambon, Fraunhofer Institute for Production Technology (Germany)
Benjamin Bulla, Fraunhofer Institute for Production Technology (Germany)
Michael Heselhaus, ZF Friedrichshafen AG (Germany)


Published in SPIE Proceedings Vol. 7282:
4th International Symposium on Advanced Optical Manufacturing and Testing Technologies: Advanced Optical Manufacturing Technologies
Li Yang; John M. Schoen; Yoshiharu Namba; Shengyi Li, Editor(s)

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