Single-point diamond turning is a useful optical fabrication method for simultaneously obtaining a smooth surface and generating an accurate shape. Generally, a single-crystal diamond tool has been used in the single-point diamond turning method and a degree of the wear on the diamond tool is unavoidable. Tool wear causes the degradation of the surface quality, surface roughness, and shape accuracy of the workpiece. Inspection of tool wear is important in improving the surface quality. A single-crystal diamond tool used in electroless nickel turning was inspected by a laser scanning microscope and a scanning probe microscope. Regular grooves were observed on the flank face of the diamond tool, and the pitch interval was the same as the feed rate. The worn distance was obtained by measuring the clearance angle and the groove length on the flank face of the worn diamond tool. The worn distance of the diamond tool was 1.7 μm after machining electroless nickel for a 3.18 km cutting distance. The worn distance could also be obtained using the worn width on the flank face and the nose radius and was 2.05 μm, which was very close to 1.7 μm. Two methods based on the wear measurement of the flank face will be new methods to measure the worn distance of the single-crystal diamond tool.
We fabricated an X-ray beam filter housing which can acquire large-area 2-dimensional images with a designated narrow band X-ray energy which was generated from the wide energy spectrum of the X-ray beam. The filter housing consists of an array of reflectors and each reflector filters the input X-ray energy from an ordinary X-ray tube and passes an X-ray beam of quasi-monochromatic energy. With a precise alignment of the whole reflectors in the filter housing device it is possible to make the total quasi-monochromatic X-ray beams cover a large area for imaging. The substrate of the
reflector itself absorbs some of X-ray photons, which generates shadow of the layers on the image. In order to solve this problem the system was made to rotate around the focal spot of the X-ray tube during the X-ray image acquisition, which resembles the motion of a searchlight, hence there is no blind spot to the X-ray beam. At a preliminary stage we obtained images for a short exposure time of less than 1 second. Representative spectra and full field CDMAM
phantom image of 197 mm × 238 mm acquired from the filter housing rotation method are presented. And the advantage of the monochromatic X-ray against the conventional polychromatic X-ray in terms of contrast is investigated.
An x-ray microscope is a useful tool in medicine and biology. The performance of an x-ray microscope critically depends on its x-ray optics. In this paper, a Wolter type-I x-ray mirror is considered for biological applications. It was fabricated using an epoxy replication method. Fabrication tolerances (figure error and surface roughness) of the soft x-ray mirror were examined. A master mandrel was prepared using single-point diamond turning and polishing, and a mirror with axial symmetry was successfully manufactured by coating of a parting agent, epoxy molding, and separation steps. The replicated mirror showed 1.4-nm rms surface roughness and 160-nm peak-to-valley (and 34.3-nm rms) figure error. Several mirrors were manufactured from only one master mandrel.
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