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Many technical applications are only made possible through the use of ultra-precise components, especially with the functionality, ease of use or accuracy we are accustomed to. Examples of this are GPS navigation or high-resolution cameras on cell phones, ultra-fast data connections using fiber optics and mobile phone networks, micro-fluidic sensors in medical technology or ever more powerful computer chips. This article presents the technology used for this, ultra-precision manufacturing, which includes both the machines and tools used. The process parameters to be observed are also discussed. The focus of this White Paper is on ultra-precision turning, although many of the considerations can also be applied to other ultra-precision manufacturing processes like milling.

Autor: Dr. Thomas Liebrich

 

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Einführung

Ultra-precision manufacturing (UPM) represents the pinnacle of manufacturing technologies, achieving accuracy and surface quality of machined workpieces at the nanometer level. This advanced manufacturing technique plays a crucial role in modern industry, enabling the production of components that meet the highest standards of precision and functionality. This chapter provides a definition of UPM, looks at its historical development and ends with an overview of selected applications of this fascinating technology.

 

1.1 Definition of ultra-precision machining

Ultra-precision machining (UPM) is a highly specialized field within manufacturing technology that focuses on achieving highest accuracies and surface qualities. Unlike conventional machining, UPM operates at a level of precision that often reaches submicron and even nanometer scales.

UPM is a multi-disciplinary engineering discipline, heavily based on the application of metrology (dimensional and thermal), machining and production processes, materials, design, and construction as well as micro-sensors, drives, actuators or control systems. The key characteristics that define UPM include:

• Highest geometrical accuracy with dimensional tolerances less than 100 nm, e.g. minimal form deviations, often within a fraction of the wavelength of light;
• Highest surface qualities with roughness values Ra typically less than 10 nm;
• High-precision tools, very often made of diamond with sharpest cutting edges, e.g. edge radii < 1 µm and waviness of the cutting edge < 50 nm;
• Metrology to ensure lowest measurement uncertainties: due to the tolerances to be checked in the submicron range, the measurement uncertainties are extremely challenging – goal is less than 10 % of the tolerance to be checked.

This means working with tolerances reaching a relative precision of one part in 108 to 109. UPM encompasses several highly specialized machining processes.