Redefining the Diamond Cutting Edge: A Technique that Complements Nano-Metric Surface Generation

Ongoing developments in broadband digital networks and optical devices require mechanical components having nano-metric surface finishes and ultra precision shapes. Such components are processed using the technology of diamond micro-machining in which diamond tools are extensively used. However, these tools are susceptible to chemical attack at high temperatures and induce severe wear, especially when cutting ferrous materials. As a result, these diamond tools need to be redefined (i.e., resharpened) on a regular basis in order to facilitate micro-cutting and to generate nano-metric surface finishes. This paper describes a new way of diamond tool edge re-sharpening and its conditions to achieve both increased accuracy and material removal rate.