Crystalline & Chalcogenide Optical Elements

Mono-crystalline diamond tooling used in conjunction with ultraprecision, CNC machine tools are used to deterministically manufacture infrared optical filter elements to a form accuracy of λ/8 or better. These optical elements are comprised of the following materials.
Crystals: Si, Ge, ZnS, ZnSe, CaF, InSb, GaAs, LiNb
Chalcogenide: AMTIR, Amorphous Materials
Black Diamond, Lightpath Gasir, Umicore IRG, Schott
The cutting table of the diamond for machining these materials is configured with a negative rake (-20° – 35°) for optimal surface quality and tool life (see fig 1.). Diamond edge profiles can be configured with radii ranging from 0.001mm – 600mm, flat, Vshaped or split radius. K&Y Diamond can produce control waviness cutting edges over 120° tool sweep, as low as 20nm P/V.

K&Y Diamond’s state of the art manufacturing and metrology techniques provide unique capabilities for shaping diamond into complex shapes with unsurpassed accuracy.

FeatureK&Y Capability
Radius0.001mm to 600.0mm
Waviness<20nm P/V over 120°
Rake-45° - 0°, ±0.5°
Front Clearance3° - 30°, Cylindrical or Conical
Cutting profileFull Radius, Split Radius, V-Tool, Flat, Elliptical, Custom Facet
Included angle/ Sweep10° Smallest included angle 180° maximum sweep
Shank MaterialInsert Type, Carbide, Steel

K&Y Diamond Re-Lap and Re-Cone Service

K&Y Diamond has internal capacity to re-lap over 400 tools per day. All tools sent to K&Y Diamond for repair undergo incoming inspection for excessive wear or damage. Customer’s are notified if a tool requires a re-cone or repair prior to service. Re-lapped tools are turned around in one day. Re-coned tools are turned around in 1-2 weeks. K&Y Diamond will repair tools from any manufacturer.
WHEN TO SEND A TOOL TO K&Y DIAMOND FOR ‘RE-LAP’?
Contrary to popular belief, diamonds are not forever when used as tooling. Diamond tool wear is micro-fracturing of the diamond at the cutting edge, resulting in increasing surface roughness and/or grain decoration (orange peel), varying power and surface irregularity in a machined optical element. The rate of wear is a function of localized heat due to cutting and vibration. Workpiece material properties and machine dynamic stiffness are the primary drivers for heat and vibration in a machining process. There are several parameters a diamond turning technician can adjust to reduce the tool wear rate. Note: Adjusting these variables may have an adverse effect to the process in other areas.