Ultra-precision machining is often used to manufacture parts in industries that demand Ultra-precision, such as aerospace, medical, precision instruments, and biological. This article mainly introduces what ultra-precision machining is and the common ultra-precision machining processes.
What is Ultra Precision Machining?
Ultra-precision machining refers to machining technologies that achieve extremely high dimensional accuracy (usually less than 0.001mm), High-quality surface finish, and complex geometries during the manufacturing process. Unlike conventional machining, ultra-precision machining can handle difficult-to-cut and emerging materials with exceptionally tight tolerances and surface quality.
Accuracy of ultra-precision machining
The machining accuracy of ultra-precision machining can be divided into several grades according to accuracy requirements and applications, usually from micron level to nanometer level.
Micron level accuracy
Micron-level accuracy refers to the accuracy of the size, shape, and surface quality of the machined workpiece reaching the micron (μm) level. The accuracy is generally 3-0.3μm, and the roughness is 0.3~0·03μm. this level of accuracy is mainly used in high-precision precision toolings.
Nanometer level accuracy
Nano-level processing accuracy is generally 30nm, and roughness accuracy is less than 5nm. It is mainly used in ultra-precision optical components, nanotechnology equipment, integrated circuits, and other fields.
How does Ultra Precision Machining Work?
Advanced Machines
Ultra-precision machining relies on high-precision machines such as CNC centers which offer exceptional accuracy and repeatability. these machines are usually controlled by a precision control system and a low thermal expansion system to enhance dimensional stability.
High-Precision Cutting Tools
No matter laser cutting or CNC cutting tools, To achieve ultra-precision machining, the cutting tools need to achieve ultra-precision and stability before starting the machining. High-precision CNC cutting tools are made from materials such as polycrystalline diamond (PCD) and cubic boron nitride (CBN) which can provide high wear resistance and maintain their sharpness, allowing for precise cuts.
Quality Control
Ensuring accuracy in ultra-precision machining requires advanced Quality Control equipment and techniques. Equipment such as laser interferometers and non-contact surface measurement systems ensure parts meet strict specifications and tolerances.
Common Ultra Precision Machining processes
Ultra-precision turning
Ultra-precision turning also referred to as single-point diamond turning(SPDT), is a high-precision turning process performed on a CNC lathe, Using a diamond-tipped cutting tool to remove the material from Workpieces. the accuracy of Ultra-precision turning can generally reach 10-100nm. it is widely used in optical devices and optical lens manufacturing, high-precision bearings, gyroscope parts, etc.
Read more in our blog to check more details about the Guide to Diamond Turning.
Ultra-precision grinding
Ultra-precision grinding is a process that uses superabrasive grinding wheels as the main processing tool and performs ultra-micro-amount cutting on ultra-precision machines to obtain extremely high accuracy surface quality. Its accuracy can reach less than 0.1μm, and the surface roughness can reach less than 0.025μm. Ultra-precision grinding technology is mainly used in various precision parts, such as optical aspheric surfaces, semiconductor silicon wafers, super-hard high-precision molds, missile fairings, etc. Hemispheric resonant gyroscope, etc.
Wire EDM (Electric discharge machining)
Electric discharge machining is a non-contact metal machining process. It uses electric sparks generated from a high-energy pulse current on the surface of the workpiece to remove the materials of the workpiece. It is especially suitable for machining metal conductive materials with high hardness, complex shapes, and high precision requirements and is widely used in tooling-making industries. Wire EDM can achieve an accuracy level of 0.001mm.
Laser Machining
Laser machining uses a focused high-energy laser beam to locally irradiate materials to generate high temperatures, which can melt, vaporize, or cause physical and chemical changes in the material, thereby achieving cutting, welding, and drilling. The precision of laser machining can reach the micron level.
Ion beam machining
Ion beam machining uses high-energy ion beams to focus on nanometer diameters of the workpiece surface to cause sputtering and deposition. It is widely used in semiconductor manufacturing such as nanopore, integrated circuit repair, etc.
Chemical polishing
Chemical polishing combines the processes of chemical etching and mechanical grinding. It uses a polishing pad containing a chemical solution under a certain pressure and speed to grind the surface of the workpiece to the micron level smooth. Chemical polishing technology is mainly used in the semiconductor manufacturing industry.
Applications of Ultra Precision Machining
Aerospace
In the aerospace industry, ultra-precision machining is used to manufacture key parts of aircraft and rockets, such as turbine blades, compressor disks, etc.
Biomedical
In the biomedical industry, ultra-precision machining is used to manufacture medical implants such as artificial joints and dental implants.
Instrument
Ultra-precision machining is used to manufacture high-precision measuring instruments and scientific experimental instruments.
Optical components
Ultra-precision machining is used to manufacture high-precision optical components, optical instruments, optical lenses, etc.
Automotive
In the automotive industry, ultra-precision machining is used to manufacture key components such as engines and transmissions.
Conclusion
Ultra-precision machining can manufacture complex parts with extreme accuracy, and high surface finish which ensures superior performance and reliability. it also requires deep know-how about the machines and operations, KUSLA, a trusted leader in ultra-precision machining, has advanced equipment and skilled engineers, and can help you get your products done with high precision requirements.
FAQ
what is the difference between Ultra-precision machining vs traditional machining
Ultra-precision machining can achieve extremely tight tolerances and excellent surface finish in Nanometer level, while traditional machining can only achieve the usual tolerances.
Which machining method has higher accuracy and surface finish?
Ultra-precision turning produces great accuracy surface finishes as smooth as 0.01 μm Ra (average surface roughness). It is the preferred method for products that require precise tolerances that CNC milling machines cannot provide.
