Design and Development of High-Precision Hybrid Controller forUltra-Precision Non-ConventionalSingle-Point Diamond TurningProcesses

Ultra-High precision Single-Point Diamond Turning (SPDT) is a widely used machining technology for generationcomponents withoptical grade surfaces. SPDT has been widely used in different industry sectors including aerospace, biomedical, military, defense, electronics, and entertainment. By using SPDT,manufacturing of optical surfaces with roughness down to one nanometer, evenless than one nanometer, is possible. Recently, the application of non-conventional SPDT techniquesduring SPDTfor improving the outcome of the process has been emerging. Non-conventional machining techniques have been developed and used during SPDT for assisting the process from different capacities. It hasbeenrevealed that by using a sole or a combination of non-conventional techniques during SPDT,superior results in terms of optical surface roughness and surface profile accuracy could be obtained. However, non-conventional SPDT technologies are novel solutions and more research need to be undertaken in terms of optimizingthese processes and improving their performance. In this study, a novel high-precision hybrid controller is designed and developed for using in non-conventional SPDT processes. The proposed hybrid controlled has the capability of automatically and precisely control different non-conventional machining techniques during the diamond turning process.This controller could be used in a hybrid SPDT platform for controlling implemented machining techniques and synchronizing them. In addition, this hybrid controller could connect to on-machine metrology devices for in-process data acquisition, analyzing process parameters, and determining machining conditions. Thus, in-process tuning of the working parameters is possible. Results of simulations and experimental study have shown the functionalityof the developed controller with sufficient precision to be used in such ultra-precision non-conventional SPDT processes.