Development of Ultra-Smooth Diamond Tooling for Machining Lightweight Mirrors

Award Information
Agency: National Aeronautics and Space Administration
Branch: N/A
Contract: NNM04AA22C
Agency Tracking Number: 024513
Amount: $600,000.00
Phase: Phase II
Program: SBIR
Awards Year: 2004
Solicitation Year: 2002
Solicitation Topic Code: S2.05
Solicitation Number: N/A
Small Business Information
Diamond Materials, Inc.
120 Centennial Ave., Piscataway, NJ, 08854-3908
DUNS: 938685963
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Dr. Oleg A. Voronov
 Principal Investigator
 (732) 885-0805
 ovoronov@aol.com
Business Contact
 Gary Tompa
Title: Business Official
Phone: (732) 885-0805
Email: gstompa@aol.com
Research Institution
N/A
Abstract
DMI has produced functionally-graded diamond-TiC-Ti cutters for machining lightweight mirror optics, particularly those made of SiC, with high precision and with minimal wear of the cutting edge. The improved wear (relative to commercial diamond tools) is achieved by orienting diamond crystals on the tips of specially designed cutter inserts, so as to exploit the anisotropy in diamond hardness. The reduction in tip wear enhances the precision of machining in uninterrupted cuts. The advantage is most clearly seen when hard ceramics, such as SiC, are machined, but the new cutter technology also provides benefits in machining certain metallic systems. Another innovation is the fabrication of a set of spherically-shaped Diamonite? smoothers, which improve the quality of the finishing operation; thus, for the first time, giving an ultra-smooth surface finish. The combined innovations should enable the optics industry to enhance the performance of large telescopes and interferometers. In Phase I, we designed a special diamond cutting tool for SiC, manufactured samples of cutters and smoothers, conducted research on machining and smoothing of mirror materials, and proved the validity of the concept. In Phase II, we propose to develop ultra-smooth diamond tooling and diamond tool fabrication techniques. The deliverables are diamond-TiC-Ti cutters to achieve higher precision of turning and Diamonite? smoothers to realize better surface finish. In addition, procedures for the reproducible fabrication of mirror optics will be defined. In Phase III, we will implement our developed tools and techniques with end-user companies, and produce machined parts to NASA specifications. This new class of tools should also have wide applications in the machining of structural and functional ceramics.

* information listed above is at the time of submission.

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