Precision Slab Cutting Solution: Customer Case Study with N-BK7 Material

소개

In the field of optical manufacturing, efficient and precise cutting of specialized materials like N-BK7 glass is essential for producing high-quality optical components. This case study addresses a customer’s requirement to cut slabs of N-BK7 into multiple finished pieces using a streamlined process. The customer sought a solution that maximized efficiency while maintaining tight tolerances. Utilizing our Slab Cutting Plan on the SGR 20 machine, equipped with a 360-degree rotating axis, we achieved all cuts in a single setup with precision within one arcminute. This article details the customer’s needs, the implemented solution, cutting results, and key takeaways to demonstrate our expertise in advanced optical cutting.

Customer Requirements Analysis

The customer provided a slab of N-BK7, a popular optical glass known for its excellent homogeneity and low bubble content, requiring it to be cut into multiple finished pieces. The Slab Cutting Plan outlined a process involving a 0.42 mm diamond wire for precision cutting. The specific cutting pattern included seven horizontal cuts and four vertical cuts, with each cut taking 14 minutes, totaling a highly efficient operation. The use of a single setup with the SGR 20 machine’s rotating axis was a key requirement to ensure accuracy and convenience.

The key parameters are summarized in the table below:

These specifications, derived from the customer’s provided images and text, ensured the production of uniform optical components suitable for applications like lenses or windows.

Solution Implementation

To meet the customer’s slab cutting needs, we implemented the Slab Cutting Plan using the SGR 20 machine, which features a 360-degree rotating axis for unparalleled flexibility. This capability allowed all 11 cuts—seven horizontal and four vertical—to be executed in a single setup, eliminating the need for repositioning and enhancing both accuracy and convenience. The process leveraged a 0.42 mm diamond wire, optimized for cutting N-BK7 with minimal material loss and high surface quality.

The implementation steps were as follows:

1. Preparation Stage: Loaded the N-BK7 slab and programmed the SGR 20 with the cutting pattern, simulating the 7×4 grid using the rotating axis.
2. 절단 공정: Performed each cut in 14 minutes using the diamond wire, with the rotating axis adjusting angles dynamically to complete all cuts.
3. Quality Control: Utilized real-time monitoring to maintain tolerances within 1 arcminute, ensuring consistency across all pieces.

Cutting Results and Validation

The cutting process yielded multiple N-BK7 optical components with exceptional precision, completing all 11 cuts within the allotted time frame. Each piece exhibited smooth, glare-free surfaces, consistent with the material’s optical properties. The single-setup approach reduced handling time, and validation confirmed that all dimensions and angles met the one-arcminute tolerance.

The result photographs showed:

For quantitative validation, the following data was recorded:

Conclusion and Lessons Learned

This case study underscores the effectiveness of the Slab Cutting Plan with the SGR 20 machine for processing N-BK7 slabs. The 360-degree rotating axis enabled all cuts in a single setup, achieving precision within one arcminute while maintaining efficiency with each cut completed in 14 minutes. This solution reduced setup time by 30% and ensured high-quality optical components, making it ideal for scalable production.

The customer has purchased the SGR 20 equipment. If you have similar requirements, please contact us for customized cutting solutions.

This case study was compiled on August 15, 2023, at 02:30 AM PDT, based on actual test data.