Title: High-efficiency machining of single-crystal germanium using large-radius diamond tools

Authors: Tsutomu Ohta, Jiwang Yan, Shuuma Yajima, Youichi Takahashi, Naoyuki Horikawa, Tsunemoto Kuriyagawa

Addresses: Mitsubishi Electric Corporation, Kamakura Works, 325 Kamimachiya, Kamakura, Kanagawa 247-8520, Japan. ' Department of Nanomechanics, Tohoku University, Aramaki Aoba 6-6-01, Aoba-ku, Sendai 980-8579, Japan. ' Mitsubishi Electric Corporation, Kamakura Works, 325 Kamimachiya, Kamakura, Kanagawa 247-8520, Japan. ' Tokyo Diamond Tools Mfg. Co., Ltd, 3-5 Nakane 2chome, Meguroku, Tokyo 152-0031, Japan. ' Tokyo Diamond Tools Mfg. Co., Ltd, 340-3 Imai, Okaya, Nagano 394-0001, Japan. ' Department of Nanomechanics, Tohoku University, Aramaki Aoba 6-6-01, Aoba-ku, Sendai 980-8579, Japan

Abstract: Round-nosed diamond tools with various nose radii are used for cutting single crystalline germanium and fundamental machining characteristics are examined. It is found that when cutting with small radius tools, the principal cutting force is dominant and crater wear on rake face is significant. However, when cutting with large radius tools, the thrust force becomes significant and tool failure is caused by formation of an angular flank wear land. The use of a large radius tool at a high tool feed improves ductile machining efficiency by a factor of over ten, thus is useful for reducing infrared lens manufacturing costs.

Keywords: germanium; diamond turning; ductile machining; tool wear; cutting force; tool radius; high-efficiency machining; thrust force; tool failure; diamond tools; infrared lens manufacturing.

DOI: 10.1504/IJSURFSE.2007.016691

International Journal of Surface Science and Engineering, 2007 Vol.1 No.4, pp.374 - 392

Published online: 15 Jan 2008 *

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