Ultra-precision cutting of an aluminum alloy Improvement of the cutting edge shape using a straight diamond tool

In recent years, optical scanning parts are in demand for use in high-performance information systems for reducing optical aberration, scatter, and diffraction rays. Laser printers use many scanning optical system parts, such as polygon mirrors and photoconductor drums. Polygon mirrors are created by polishing a plating or glassy material to a mirror finish. In this study, we shorten the manufacturing process to improve the productivity and ultra-precision cutting technology of polygon mirrors made of aluminum. It is necessary to improve geometric surface roughness and remove tear marks and scratch marks that are caused during the mirror cutting of the Aℓ alloys in this study. Generally, the mirror cutting of Aℓ alloys use a straight diamond tool that is inclined. However, this method is difficult because of the short range of the tool setting angle. Therefore, a straight diamond tool is attached to a double end cutting edge to extend the tool setting angle and the influence of surface defects is examined. In addition, the influence of the rake angle, side rake angle, depth of cut on the surface roughness and cutting force are considered for the ultra-precision cutting of the Aℓ alloys, which is made easier by the use of a double facet tool.