Ultra-precision machining of micro grooves on electroless nickel plated material

Abstract

Ultra-precision machining of micro grooves was carried out to fabricate very high resolution and high accuracy prismatic light guide for CD or DVD pickup lenses. The main objective of this work was to evaluate the performance and suitability of single crystal diamond tools during micro grooving on electroless nickel plated die materials. Effects of different machining parameters on overall machining performance were also investigated. Experimental results revealed that long distance (50km) machining of micro grooves on electroless nickel is possible with a single crystal diamond tool of 0A? rake angle without any significant tool wear. Some groove wear found on the rake face did not affect the machined surfaces. The surface roughness range of the machined workpieces was found to be 4-6 nm. Both thrust and cutting forces showed an increasing trend with increasing machining distance, however, magnitude of the thrust forces were found to increase more than the cutting forces.