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Ultra-precision machining processes fall under the nanotechnology regime Ion beam machining, is a process that functions at the atomic level, is known to be an ultra-precision machining process This inert gas ion process employs argon ions or other inert gas ions such as Kr and Xe at high kinetic energy levels of the order of 10 KeV to bombard and erode the surface of the workpiece By these means, the parent atoms are ejected by collision and emission by a phenomenon known as the ion sputter The penetration depth of an ion at 1 KeV as estimated from electron diffraction patterns is about 5 m The method neither generates heat to an intolerable level since the material removed is in units of atoms and in a random manner nor does it cause any significant mechanical strain damage in the machined surface layer Some of the argon ions are retained, substituting displaced workpiece atoms This process has a machining resolution of about 10 nm The ion-beam milling process (Figure 130), which uses a DC discharge, is a good example of an energy beam machining process



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Fig 130: A model of the ion beam machining/sputtering process [1]

Control information can be encoded on a cam. A cam is a wheel with one or more projections. In the simplest form, a cam is a round wheel mounted o -center, like the eccentric cam shown in Fig. 7-6. Eccentric doesn t mean





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As temperature variations can affect the accuracy of a process [20, 22], manufacturing engineers must pay attention to these variations when there is a need for accuracy and precision The thermal expansion of the components of a machine tool, which causes distortion, is an important factor that controls the precision of a machine tool The sources of heat may originate internally such as in bearings; machine ways, motors, and heat generated from the cutting zone, or may be external, such as from nearby furnaces, heaters, sunlight, and fluctuations in cutting and ambient temperature [6] The use of high-speed machining spindles with a coolant supply such as the one shown in Figure 131 is desirable [21] These considerations are particularly important in precision and ultra-precision machining, including diamond turning, where dimensional tolerances and surface finish have to necessarily be in the nanorange

Fig. 7-6.

Fig 131:

A high-speed spindle with a coolant supply minimizes temperature variations [21]

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that it lives alone in a big house collecting cats It literally means that it is o -center The cam provides one way to convert rotary motion (the turning of the cam) into linear motion Look at the cam from a xed point of view As the cam rotates its edge gets closer and closer to us, until it reaches its closest point and then the edge retreats This moving edge can be used to trigger a switch, push a lever, or slide a bar When the cam pushes on a lever or rod, the pushed piece is called a cam follower Followers may have rollers or some other friction-reducing scheme on their end to keep them from rubbing on the cam and slowing things down Cams don t have to be round, but can have any shape desired.

Precision component manufacturing increasingly requires specifying tolerances on some component features that are so rigid that mere shop floor or operation-induced temperature changes can cause measured dimensions to vary significantly Dimensions are usually specified at 20 C because ISO1 fixes the standard reference temperature for industrial length measurements at 20 C A workpiece or gauge departing from this temperature by even a few degrees can result in unexpected changes in critical dimensions For example, a gauge that reads 7533 mm, say, 30 times in succession while measuring a 7520 mm diameter will have a remarkable repeatability precision but will not give accurate readings It then becomes necessary to make a compensation for deviations from the reference temperature (20 C) as environmental conditions can also affect precision measurements

1 Nakazawa, H, Principles of Precision Engineering, Oxford University Press, USA, 1994 2 Taniguchi, N, The state of the art of nanotechnology for processing of ultra precision and ultra fine products , Journal of the American Society of Precision Engineering, 1994, Vol16, No1, 5 24

Cams may also consist of pins or pegs stuck into a wheel, so long as the cam follower doesn t get stuck on them Figure 7-7 shows a more intricate cam, a cam follower, and the motion of the follower traced out on a graph Multiple cams can be stacked on the same shaft, each one controlling some aspect of a machine The cams don t have to be individual disks, but can be a solid drum or bar of material that has been shaped to act like a series of cams Music boxes use this type of mechanism, a rotating drum with pins on it that pluck the musical tines The only limit to a cam s shape is your imagination Changing the programming on a cam-driven machine requires that you take it apart and replace pieces inside of it.

Load coefficient CL(at e = 05)

+ is)(k 2 -

This may not be the most e cient way to change the machine s action More advanced cams let you replace their bumps without taking things entirely apart, but this is still a clumsy way to program a robot..

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