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Fabrication processes for precision mechanical surfaces, such as fixed abrasive grinding, have been applied to a variety of hard materials. The resulting surfaces are smooth and flat with a characteristic surface finsh. On hard steel surfaces, the surface finish is typically on the order of 0.5 pm cla , however, significantly better finishes can be obtained for a small infeed rate as during a spark-out pass made without changing the depth of cut. For these conditions, surface finishes of less than 0.05 pm cla are possible. For applications to optical surfaces, mechanical strength is not an important consideration and the materials tend to be much more brittle. The surfaces produced by fixed abrasive grinding of these materials are characterized by considerable subsurface damage on the order of the abrasive grain size. This damage is typically removed by loose abrasive grinding followed by polishing with a friable abrasive such as cerium or aluminum oxide. However, the figure accuracy built into the original ground surface is often compromised as a result of this polishing operation. The objective of the work at the Precision Engineering Center at North Carolina State University is to study precision material removal processes to define the parameters that influence the transition from ductile to brittle material removal. This involves the identification and measurement of the material properties of interest, geometrical analysis of the material removed, and characterization of the cutting tool and the machine dynamics.

Ductile/brittle transition and development of ductile mode grinding technology.