• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.10a
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• pp.957-960
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• 1997

A complete quantitative understanding of DT has been difficult because the process represents such s broad field of research. The experimental measurement of tool force is a single area of DT which still covers a wide range of possibilities. Here are numerous parameters of the process which affect cutting forces. There are also many turnable materials of current interest. To obtain information toward a better understanding of the process, a few cutting parameters and materials were selected for detail study. It was decided that free-oxygen copper and 6061-T6 alloy aluminum would be the primary test materials. There are materials which other workers have also used because of there wide use in reflective applications. The experimental phase of the research project began by designing tests to isolate certain cutting parameters. The parameters chosen to study were those that affected the cross-sectional area of the uncut chip. The specific parameters which cause this area to vary are the depth of cut and infeed per revolution, or feedrates. Other parameter such a tool nose radius and surface roughness were investigated as they became relevant to the research.

• The Bulletin of The Korean Astronomical Society
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• v.39 no.2
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• pp.103-103
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• 2014

Manufacturing of lens and mirror using Diamond Turning Machine (DTM) offers distinct advantages including short fabrication time and low cost as compared to grinding or polishing process. However, the DTM process can leave mid-frequency error in the optical surface which generates an undesirable diffraction effect and stray light. The mid-frequency error is expected to be eliminated by mechanical polishing after the DTM process, but polishing of soft surface of ductile aluminum is extremely difficult because the polishing process inevitably degrades the surface form accuracy. In order to increase its surface hardness, we performed electroless nickel plating on the surface of diamond-turned aluminum (Al-6061T6) off-axis mirrors, which was followed by the 6-hour-long baking process at $200^{\circ}C$ for improving its hardness. Then we polished the nickel plated off-axis mirrors to remove the mid-frequency error and measured polished mirror surfaces using the optical surface profilometer (NT 2000, Wyko Inc.). Finally, we ascertained that the mid-frequency error on the mirror surface was successfully removed. During the whole processes of nickel plating and polishing, we monitored the form accuracy using the ultra-high accurate 3-D profilometer (UA3P, Panasonic Corp.) to maintain it within the allowable tolerance range (< tens of nm). The polished off-axis mirror was optically tested using a visible laser source and a pinhole, and the airy pattern obtained from the polished mirror was compared with the unpolished case to check the influence of mid-frequency error on optical images.

• The Bulletin of The Korean Astronomical Society
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• v.38 no.2
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• pp.83.1-83.1
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• 2013

선형비점수차를 완벽하게 제거한 비축반사경 이론을 천체 관측용 분광기의 전단 광학계 등에 응용하면 색수차가 없는 기기 제작이 가능하다. 이러한 비축 반사경은 DTM(Diamond Turning Machine)을 이용하여 알루미늄으로 만들면 제작 시간이 단축된다. 그러나 DTM을 이용해 알루미늄과 같이 무른 금속을 가공할 경우 툴마크가 발생하게 된다. 툴마크는 회절현상을 발생시키며 이러한 회절현상은 알루미늄 반사경을 이용한 광학계 개발에 제약이 된다. 툴마크는 DTM 가공 이후 연마를 통해 제거할 수 있지만 알루미늄의 무른 특성으로 인해 연마 과정에서 반사경의 형상이 변할 가능성이 크다. 이러한 알루미늄 반사경의 형상 변화를 최소화하기 위한 방법으로는 알루미늄 반사경 표면에 무전해니켈도금을 하는 것이다. 하지만 도금 과정에서 반사경의 형상이 변할 가능성이 있기 때문에 두가지 방법을 사용하여 툴마크를 제거할 계획이다. 첫 번째 방법은 DTM 가공된 알루미늄 반사경을 5 um의 무전해니켈도금 이후 연마하여 툴마크를 제거하고 반사율 증가를 위해 그 위에 다시 알루미늄 코팅을 하는 방법니다. 두 번째 방법은 100 um의 무전해니켈도금 이후 DTM 가공을 하고 다시 연마를 통해 툴마크를 제거하는 방법이다. 이번 발표에서는 툴마크를 제거하기 위한 2가지 방법의 장단점을 확인하고 툴마크를 제거한 알루미늄 반사경을 제작하기 위한 과정을 설명하였다. 본 연구에서 개발한 비축 반사경은 서울대학교 창의연구단의 광학/적외선 카메라 CQUEAN의 차세대 모델에 적용할 계획이다.

• The Bulletin of The Korean Astronomical Society
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• v.41 no.2
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• pp.65.1-65.1
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• 2016

일반적으로 천체 망원경에 사용되는 반사경은 유리 소재로 제작된다. 그러나 알루미늄을 반사경 소재로 사용하면 광기계구조물과 반사경의 열팽창계수가 유사하여 치수 안정성이 높다는 장점이 있다. 뿐만 아니라 다이아몬드 선삭 기계 (Diamond Turning Machine, DTM)를 이용할 수 있기 때문에 반사경의 가공 시간 및 제작 비용을 절감할 수 있다. 본 연구에서는 알루미늄 합금 (Al6061-T6)을 소재로 구경 150 mm, 초점거리 600 mm인 포물면 반사경을 제작하였다. 우선 DTM을 이용해 알루미늄을 가공하였는데, 이 때 표면 조도와 관련된 고주파 오차 (High Frequency Error, HFE)가 발생한다. 따라서 표면 조도를 향상시키기 위한 추가적인 공정으로써 가공된 표면을 도금한 후 열처리를 하고, 폴리싱과 이중 코팅을 거쳐서 최종 반사경을 얻었다. 각 단계별 공정을 마친 후에는 접촉식 및 광학식 형상 측정 방법으로 표면 측정을 실시하여 이를 분석하였다. 본 발표에서는 각 공정 단계에서의 반사경 표면 분석 결과를 설명할 것이며, 제작된 알루미늄 반사경과 기존의 유리 소재의 반사경을 성능 면에서 비교할 것이다.

• Korean Journal of Optics and Photonics
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• v.17 no.5
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• pp.412-419
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• 2006

We design and fabricate an autostigmatic null lens system assembled in a fixed tube mount in order to evaluate the shape of an aluminum hyperbolic mirror with the diameter of 300 mm and the f-number of 1.98, which is fabricated by a high precision aspherical DTM (diamond turning machine). Also, we evaluate the degree of shape of the aspherical mirror by this autostigmatic null lens testing method. The autostigmatic null lens system assembling in a fixed tube mount has several advantages of light weight, good mechanical stability, etc. The permissible fabricating limits of null lenses and a mount are determined by considering various tolerances to assure the measurement reliability.

• The Bulletin of The Korean Astronomical Society
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• v.42 no.1
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• pp.56.4-57
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• 2017

The Schwarzschild-Chang off-axis telescope is a "linear astigmatism-free" confocal system. The telescope comprises two pieces of aluminum-alloy freeform mirrors that are fabricated with diamond turning machine (DTM) process. We designed optomechanical structures where optical components in the telescope system can be adjustable on a linear stage. Optomechanical deformation caused by the weight of system itself and its temperature variation is analyzed by the finite element analysis (FEA). The results show that the deformation is estimated in the tolerance range. For the optic-axis alignment of telescope system, three-point alignment (TPA) method is chosen. The TPA method uses three parallel lasers and a plane mirror. Point source images were taken from collimated light and field observation. The performance of optical system was tested by point spread function and aberration measurement of the point sources.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.1
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• pp.92-99
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• 2014

An aspherical lens, which resolves several problems with a spherical lens,typically serves asa key part of an optical system. Generally, an aspherical lens is fabricated using a diamond turning machine or by mean of injection molding. However, residual stress and/or tool marks can arise when using a commercial fabricating method such as DTM or injection molding. A polishing process, thus, is commonly used to obtain a high-precision aspherical lens. In this study, a polishing method using MR fluid was applied to minimize several problems, in this case residual stress and the creation of tool marks, during the cutting process. The MR polishing system was developed to polish aspherical lenses. A series of experiments were performed to obtain a very fine surface roughness. PMMA (the lens material for molding) was used as a workpiece, and the gap size, magnetic field intensity, wheel speed and feed rate were selected as the parameters in this study. Finally, a very fine surface roughness of Ra=2.12nm was obtained after MR polishing.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.10
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• pp.1189-1193
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• 2012

The Miniaturized Fingerprint Imager (MFI) is a slim optical mouse that can be used as an input device for application to wireless portable personnel communication devices such as smartphones. In this study, we have fabricated key optical components of an MFI, including the illumination optical components and imaging lens. An LED beam-shaping lens consisting of an aspheric lens and a Fresnel facet was successfully machined using a diamond turning machine (DTM). A customized V-shaped groove for beam path banding was fabricated by the bulk micromachining of silicon that was coated with aluminum using the shadow effect in thermal evaporation. The imaging lens and arrayed multilevel Fresnel lenses were fabricated by electron beam lithography and FAB etching, respectively. The proposed optical components are extremely compact and have high optical efficiency; therefore, they are applicable to ultraslim optical systems.