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3 Machining Plastic Optics PRECISION ENGINEERING CONSORTIUM 2017 ANNUAL REPORT VOLUME XXXI January 2018 Sponsors: Los Alamos National Laboratory Oculus VR Faculty: Thomas Dow Ronald Scattergood David Muddiman Mark Pankow Victoria Miller Brendan O’Connor Graduate Students: Charan Bodlapti Noa McNutt Undergraduate Students: Alyssa Edwards Staff: Kenneth Garrard Anthony Wong Beth Deakle Consultants: Karl J. Falter Stephen Furst Proprietary Release subject to the terms and conditions of the Precision Engineering Consortium Membership Agreement and North Carolina State University Office of Technology Transfer nondisclosure agreements. Table of Contents Summary i 1. Balloon Experimental Twin Telescopes for Infrared Interferometry Ken Garrard, Stephen Furst and Thomas Dow 1 2. The Role of Built Up Edge in Diamond Tool Wear When Machining Steel Brandon Suit and Thomas Dow 29 3. Machining Plastic Optics Charan Bodlapati, Anthony Wong and Thomas Dow 57 4. Selection of Surrogate Material to Study Dry Machining of Plutonium Noa McNutt, Thomas Dow, Alyssa Edwards, Ken Garrard and Anthony Wong 81 5. Finding Natural Frequency of a Piezoelectric Load Cell Alyssa Edwards and Thomas Dow 115 6. Microscale Lens Array: Focused Ion Beam Milling of Microscale Features Anthony Wong 125 7. Multi Lens Array – II: Indentation and Creation of the Mold Gaurav Dave, Sriraghav Sridharan and Mark Pankow 143 8. High Spatial Resolution Infrared Mass Spectrometry Imaging Mark Bokhart, Milad Nazari, Måns Ekelöf, Ken Garrard, Jeffrey Manni and David Muddiman 163 9. Mass Spectrometry Imaging Software Ken Garrard, Mark Bokhart, Milad Nazari and David Muddiman 183 10. Characterization of Single Abrasive Grit With Force and Visualization Techniques David Gebb and Thomas Dow 201 11. Design of a Microfluidic Device to Extract Dyes From Fibers for Forensic Analysis Sean Gunning, Ken Garrard, Stephen Furst and Thomas Dow 245 Personnel 253 Graduates of the PEC 263 Academic Program 265 Fact Sheet 273 SUMMARY The goals of the Precision Engineering Consortium (PEC) are: 1) to develop new technology in the areas of precision metrology, actuation, manufacturing and assembly; and 2) to train a new generation of engineers and scientists with the background and experience to transfer this technology to industry. Because the problems related to precision engineering originate from a variety of sources, significant progress can only be achieved by applying a multidisciplinary approach; one in which the faculty, students, staff and sponsors work together to identify important research issues and find the optimum solutions. Such an environment has been created and nurtured at the PEC for 34 years and the 100+ graduates attest to the quality of the results. The 2017 Annual Report summarizes the progress over the past year by the faculty, students and staff in the Precision Engineering Consortium. During the past year, this group included 3 faculty, 2 graduate students, 1 undergraduate student, 2 full-time technical staff members and 1 administrative staff member. This diverse group of scientists and engineers provides a wealth of experience to address precision engineering problems. The format of this Annual Report separates the research effort into individual projects but there is significant interaction that occurs among the faculty, staff and students. Weekly seminars by the students and faculty provide information exchange and feedback as well as practice in technical presentations. Teamwork and group interactions are a hallmark of research at the PEC and this contributes to both the quality of the results as well as the education of the graduates. A brief abstract follows for each of the projects and the details of the progress in each is described in the remainder of the report. 1. Balloon Experimental Twin Telescopes for Infrared Interferometry (BETTII) The NASA BETTII is designed to study the infrared emissions from star formation and active galactic nuclei through a double-Fourier Michelson interferometer located on a balloon at an altitude of 37 km. The BETTII external optics include a pair of identical beam-reducing, four- mirror telescopes, each with a 522 mm aperture off-axis segment of a parabolic surface. These telescopes were designed, built and assembled at the NC State University Precision Engineering Consortium and are composed entirely of thin-walled aluminum components. The mounting structure is designed to be lightweight and stiff to reduce thermal equilibration time in the rarified air at the edge of space and to maintain robust alignment of the optical elements. The mounts also prevent deformation of the large optical elements via custom-build kinematic Kelvin couplings and fixed-load clamps; the maximum form error of the optical surfaces are 300 nm RMS. i Proprietary Release subject to the terms and conditions of the Precision Engineering Consortium Membership Agreement and North Carolina State University Office of Technology Transfer nondisclosure agreements. 2. The Role of Built-Up Edge (BUE) in Diamond Tool Wear When Machining Steel Despite its potential in many applications, diamond turned steel has long been considered improbable due to the inability to attain acceptable surface roughness and form. These difficulties lie in the rapid changes of the tool geometry due to wear and workpiece adherence. Experiments were conducted to investigate the effect of tool wear and workpiece adherence on the tool geometry and the subsequent bulk temperatures of the diamond tool, machining forces and chips produced. The results conclude that workpiece pickup dominates changes in effective tool geometry by nearly two magnitudes in size compared with tool wear. Finite element simulations were performed of the chip formation process with and without the dominating workpiece adherence. Comparatively, the geometry of workpiece adherence produces a more efficient cutting process despite the expected negative effects on the generated surface. Force results with the addition of the BUE geometry closely aligned with those of the experimental results, while simulations with the theoretical tool geometry produced forces much higher than the experimental results. Experimental chip thicknesses also matched closely with the workpiece adherence addition to the tool. This adherence acts as a protecting layer on the tool due to its low thermal conductivity in comparison to diamond. More heat flows through the workpiece and chip because the effective tool is no longer a heat sink. Workpiece adherence has a significant effect on the chip formation process when diamond turning steel in comparison to tool wear effects. 3. Machining Plastic Optics Polymers play a vital role in the optical industry. They have low specific mass, excellent optical properties when compared to mineral glasses and are a commonly used for manufacturing lenses. Single point diamond turning is widely used to machine plastic lenses. However, information on the parameters that can optimize the surface finish and minimize diamond tool wear during machining of plastics is lacking. The goal of this research is to address these two problems: surface finish and tool wear for several plastic materials. Three polymers are being used in this research: Poly (methyl Methacrylate) (PMMA), Polycarbonate (PC) and Zeonex®. This report covers the initial results of the project and the challenges faced during diamond turning of these three materials. 4. Selection of Surrogate Material to Study Dry Machining of Plutonium The goal of this project is to study the onset of built-up edge on a carbide tool during dry machining of plutonium ( - phase Ga Alloy [3]). This phenomenon degrades the surface finish as well as the figure error of the surface. Material properties were surveyed and experiments conducted to find a surrogate material that would behave in a manner similar to plutonium but without the health issues related to that radioactive material. Several materials ii Proprietary Release subject to the terms and conditions of the Precision Engineering Consortium Membership Agreement and North Carolina State University Office of Technology Transfer nondisclosure agreements. including Oxygen Free High Conductivity (OFHC) annealed copper, 1100 aluminum and 1199 aluminum were machined with different Kennametal Carbide Tools on a precision lathe. A series of experiments involving non-overlapping cuts were made with each of these materials and the surface geometry, cutting forces and tool pickup were measured. The results indicated that 1199 (pure) aluminum exhibits the pickup problem observed with plutonium. After choosing the 1100 aluminum, it was used in experiments involving overlapping cuts. The 1199 aluminum develops the most pickup at high cutting speed and low depth of cut. Now that a surrogate material has been identified, the next step will be to verify that changes in these parameters will influence the pickup in the same way as plutonium. 5. Finding Natural Frequency of a Piezoelectric Load Cell This report discusses a method of determining the natural frequency of a piezoelectric load cell used in dynamic force measurement. The experiment showed that the natural frequency of the tool holder and load cell ranges between 11-12 kHz. To create this impulse, 4 lb. fishing line was secured around the tool holder/load cell system. The applied impulse is created by loading the fishing line slowly until it snaps suddenly. This procedure disconnects the load cell from the loading system so that the load cell is not subjected to a continuous or repeated excitation.
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