User: Confidential
Contact: Dr. Ralf Dupont, Levicron
Date: March 2015
Laser reflector machining (brass)
An accurate deflection of laser beams freeform mirrors with a surface finish of better 10 nm Ra is required. The machining example shows the freeform creation of such a reflector based on a polynomial function. A Levicron tool spindle type ASD080H25 on an ultra-precision machining center with slow-tool servo function and a diamond ball end mill R2 were used.
The rough cutting was done with a standard carbide tool at 80.000 rpm, 1 mm cutting depth and 0.4 mm feet rate per cutting edge. As a result, the rough cutting time was 45 min. On the other side, the finish cutting was done at 5 micron cutting depth and a feedrate of 5 micron per cutting edge at 80.000 rpm. Finish cutting time: 24h.
Surface finish result: 7 nm Ra.
Watch this video
Information and results
Application:
Machining of a laser reflector, MS58, D 120 mm
Machine:
UL-Ultra MTC 250 (UP, 3 axes, slow-tool servo mode)
Used Machining spindle:
ASD080H25 at 80,000 rpm
Roughing
Tool: Carbide ball end mill, D4
Cutting depth: 1 mm depth, 0.5 mm feed rate per cutting edge and revolution
Roughing time: 45 minutes
Finishing
Tool: Ball-end MD (monocrytaline diamond), D4
Cutting depth: 5 micron depth at 5 micron feedrate per tooth
Finish machining time: 24 hours
Achieved surface finish
< 7 nm Ra
