Machinability of rapidly solidified aluminium alloy for optical applications

The production of metal mirrors and critical components for optical devices and aerospace application requires extreme high accuracy and outstanding surface quality. Thus, to achieve such high dimensional accuracies, they are being mainly produced through ultra-high precision machining. Aluminium alloys have been used in the production of components for optics application as well as spaceborne for so many years but with the advancement in technology and demands for a superior material, a new modified grade of aluminium was developed by a rapid solidification process. These grades exhibit a much better mechanical and physical properties while having a finer microstructure. The only downside is the limited research in the correlation of surface roughness and reflectance when single point diamond turned. In this study, rapidly solidified aluminium RSA 905 were used to investigate the effect of varying the cutting parameters on the machined surface finish and its corresponding surface reflectance. The cutting parameters were cutting speed, feed rate and depth of cut. The surface roughness was measured using Taylor Hopson PGI Profilometer while the reflectance factor was measured by using VERTEX 80v Spectrometer. The results were used to develop two predictive models namely; response surface and artificial neural network which have indicated a very high accuracy to the experimental measurements. Finally, the results were very promising for the diamond turning of RSA 905 where it has achieved a very low values of surface roughness and high reflectance in the visual range without the need of any additional production/fabrication steps and to ensure that bi-metallic binding does not take place in extreme low temperatures. Therefore, RSA 905 is a very promising material for optical applications in the visual spectrum