Feasibility of cost-effective ultra-precision diamond turning using ceramic bearing spindle

Fabrication of super finished surfaces is a challenging and expensive technology. The present study reveals a cost-effective methodology of producing mirror finish on difficult-to-machine lead-free brass by ultra-precision diamond turning. Ultra-precision face-turning has been performed in an economically developed machine tool comprised of a ceramic bearing spindle. A mirror surface finish has been achieved on the workpiece with average surface roughness from 7 to 51 nm. The axial spindle drift was small; however, a marginal spindle drift has induced small amplitude periodic fluctuation of surface profile and center groove on the machined surface. Additionally, the amplitude of machine tool vibration has appeared in the nanometer level. Negligible tool wear has been observed as well. Moreover, the ultra-precision machining performed in the present study was economically and environmentally sustainable.