Industry can do it

Cranfield Precision Division of Fives Landis Ltd. Woburn House, 3 Adams Close Kempston, Bedford MK42 7JE Tel: +44 (0) 1234 312 820

with support from the Grinding | Ultra Precision global locations

Fives Landis Corp. Fives Landis Ltd. Daisho Seiki Corporation 16778 Halfway Blvd. Eastburn Works, Road 2-1, Kunimidai 6-Chome, Ishinomiya Hagerstown, MD 21740 Cross Hills Hyogo 669-1135 UNITED STATES West BD20 7SD JAPAN Tel: +1 301 797 3400 UNITED KINGDOM Tel: +81 797 62 5500 Tel: +44 (0) 1535 633 211 GRINDING | ULTRA PRECISION ULTRA GRINDING|

Fives Landis GmbH Fives Giustina S.r.l. Dreifelderstrasse 42 Corso Lombardia 79 70599 Stuttgart San Mauro Torinese, Torino, 10099 GERMANY ITALY Tel: +49 (0) 711 45 11 45 Tel: +39 011 222 8621 Cranfield Precision Engineering Partnership Fives Grinding Mexico Shanghai Fives Automation & Circuito Aguascalientes Norte # 151-4 Processing Equipment Co., Ltd Parque Industrial Valle de Aguascalientes Guangzhou Branch office _ San Francisco de los Romo Plant No. 12, American Industry Park Aguascalientes C.P. 20358 No. 48, Hongmian Ave. MEXICO Huda District, Guangzhou, 510800 Ultra-precision technologies: process development, Tel.: +52 449 688 5118 CHINA Tel: +86 (0) 20 3770 7471 precision machine design & process technology improvement Renowned legacy names: www.fivesgroup.com [email protected] Industry can do it – R1.2 reserved – All rights © 2021 – Fives Copyright Bryant, Cincinnati, Cranfield Precision, Daisho, Gardner, Giustina and Landis 24 1 OVER 50 YEARS OF SPECIAL-PURPOSE PROJECTS

1970s — Large scale metrology CRANFIELD PRECISION — Ultra-precision grinding for primary development of computer hard disk read ENGINEERING PARTNERSHIP write heads

1980s — Diamond turning, a erospace and defense — World’s first CNC orbital cam grinder GRINDING | ULTRA PRECISION 1990s Fives and its dedicated Grinding | Ultra Precision teams - over — Optical metrology for 700 people globally - offer a complete range of grinding and space telescopes specialist ultra-precision machines, plus a comprehensive — Precision grinding and range of systems, grinding accessories and service/support metrology for satellite optics programs.

Located in Bedford, UK, Cranfield The strong links to university research 2000s Precision® teams have over 50 years groups and trade associations give — Micromachining and hard of experience in precision machine Cranfield Precision® the capacity to turning design and manufacture of world- undertake projects ranging from R&D — Silicon wafer manufacture leading ultra-precision machine and process consultancy to complete and measurement tools. machine design and manufacture.

The business area encompasses ultra-precision machine tools, 2010s precision measuring systems and — Diamond turning for custom designed special purpose brightness enhancement film microreplication used machines. in advanced displays — High precision boring and orbital grinding for large engine cranks 2020s Aerospace Bearings Computing/Semiconductor Defense Manufacturing — Ultra-precision grinding for optics, freeforms, head-up displays, optical molds and precision bearings Energy Medical Optics Astronomy Transmission — Large optic manufacture for EUV semiconductor 2 lithography 3

CASE PROCESS DEVELOPMENT FOR OPTICAL MOLDS STUDY MACHINING PROCESS DEVELOPMENT THE PROBLEM Gain access to our facilities, resources and ultra- precision development machines and collaborate Manufacture high precision optical molds used with us to improve your machining processes and in vehicle head-up displays (HUD) and camera develop new, market leading products. lenses, for automotive and mobile applications. Molds, which often require complex and freeform — Develop a new product geometry, are made from materials that are — Improve your component specification difficult to grind (stavax and tungsten carbide), — Solve a complex toolpath problem thus require many hours of post-grinding — Try new processes corrective polishing. — Reduce your R&D overhead — Free up your machinery for production

PROCESS TECHNOLOGY THE SOLUTION IMPROVEMENT Cranfield Precision engineers developed a solution that takes the mold surface design and With over 50 years experience in ultra-precision generates the necessary grinding operations for machine and process development, let Cranfield the freeform and complex geometries. Tooling is Precision work with you to employ proven analysis and design techniques to enhance your capabilities. carefully designed, selected and then tested in our ultra-precision machining lab. The complex and — Solve production problems freeform molds are ground using unique grinding — Update old production equipment machinery that has class-leading stiffness, — Enhance your software capabilities damping and thermal stability. — Make high quality parts — Improve your machine capability — Develop a new manufacturing process

THE RESULT PRECISION DESIGN — Low form error Develop a specification with Cranfield Precision — High quality surface finish; near polish and collaborate to produce an ultra-precision quality design to your requirements. Our assembly — Minimal SSD facilities can even manufacture prototype, production and batch machines for you. — Minimal post-polishing required

— Design complex components — Upgrade existing machines or sub-assemblies — Solve work holding problems — Develop new software solutions — Improve your machine capability — Create bespoke machines

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CASE CASE PROCESS TECHNOLOGY FOR IMPROVED STUDY PRECISION DESIGN FOR VERTICAL STUDY THERMAL CONTROL COUNTERFORCE

THE PROBLEM THE PROBLEM When taking the next step toward greater production On many large machine tools, the performance of accuracy on a machine where stiffness, damping the vertical axis is often the limiting factor in the and abbe errors have been reduced to a minimum, accuracy of the machine. Traditional ball screw it is often thermal effects that remain dominant methods have inherent backlash and a limited and prevent the desired improvement in product life. For large axes, a counterforce mechanism will specification. When using standard chiller systems be required. Pneumatic and hydraulic methods for temperature control, the on/off control of the are used, but these are expensive, complex and system can often be seen imprinted in the surface all introduce hysteresis to the axis. Therefore, a of precision optics. Some fluid chillers claim ±0.1 °C new counterforce design was needed to allow control, but in order to achieve sub-micron form higher speeds and accuracies, better dynamic error across the surface of an optic, it can be performance, reduced mass and cost – particularly necessary to go further, with a target of ±0.01 °C. important where linear motors are desired.

THE SOLUTION THE SOLUTION A small thermal control unit was designed that Using CAD, FEA and test rigs, a new counterforce could be retrofitted to existing fluid control circuits mechanism was designed. A slave axis uses a on the machine. Taking the standard temperature traditional ball screw to support the mass of the control capability of a normal chiller system, say carriage but is mechanically decoupled from the ±0.1 °C, fluid temperature deviation is corrected carriage itself, through a spring system. For the further and smoothed to reduce hysteresis and master axis, linear motors and high resolution overall fluctuations. CFD was used to ensure linear encoders are used to drive and position optimal fluid flows and thorough mixing of fluids the axis, for high accuracy positioning. A position to guarantee uniform temperatures of all circuits. demand is sent to the master axis, simultaneously ‘followed’ by the slave axis to provide a counterforce to the carriage mass.

THE RESULT THE RESULT Machine Fluids Temperature Control — Multiple circuits controlled to better — A patented, high accuracy, high speed, than ±0.01 °C, including motor cooling, counterforce solution for large axis mass hydrostatic oil and process cutting fluid — Successfully implemented as an upgrade — Sub-micron form errors across ground to existing customer machines, 25 years component surfaces – no corrective after the original machine was installed. form polishing required As well as new, large optics grinders — Scalable solution for larger machines with freeform capability and sub-micron and fluid volumes positioning accuracy

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