Strategies for single-point diamond machining a large format germanium blazed immersion grating

R. C. Montesanti; S. L. Little; P. J. Kuzmenko; J. V. Bixler; J. L. Jackson; J. G. Lown; R. E. Priest; B. E. Yoxall

doi:10.1117/12.2234248

22 July 2016 Strategies for single-point diamond machining a large format germanium blazed immersion grating

R. C. Montesanti, S. L. Little, P. J. Kuzmenko, J. V. Bixler, J. L. Jackson, J. G. Lown, R. E. Priest, B. E. Yoxall

Proceedings Volume 9912, Advances in Optical and Mechanical Technologies for Telescopes and Instrumentation II; 991233 (2016) https://doi.org/10.1117/12.2234248
Event: SPIE Astronomical Telescopes + Instrumentation, 2016, Edinburgh, United Kingdom

Abstract

A large format germanium immersion grating was flycut with a single-point diamond tool on the Precision Engineering Research Lathe (PERL) at the Lawrence Livermore National Laboratory (LLNL) in November – December 2015. The grating, referred to as 002u, has an area of 59 mm x 67 mm (along-groove and cross-groove directions), line pitch of 88 line/mm, and blaze angle of 32 degree. Based on total groove length, the 002u grating is five times larger than the previous largest grating (ZnSe) cut on PERL, and forty-five times larger than the previous largest germanium grating cut on PERL. The key risks associated with cutting the 002u grating were tool wear and keeping the PERL machine running uninterrupted in a stable machining environment. This paper presents the strategies employed to mitigate these risks, introduces pre-machining of the as-etched grating substrate to produce a smooth, flat, damage-free surface into which the grooves are cut, and reports on trade-offs that drove decisions and experimental results.

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R. C. Montesanti, S. L. Little, P. J. Kuzmenko, J. V. Bixler, J. L. Jackson, J. G. Lown, R. E. Priest, and B. E. Yoxall "Strategies for single-point diamond machining a large format germanium blazed immersion grating", Proc. SPIE 9912, Advances in Optical and Mechanical Technologies for Telescopes and Instrumentation II, 991233 (22 July 2016); https://doi.org/10.1117/12.2234248

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