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ZNS sub-nano roughness manufacturing process based on tool mark suppression
Optics Express
|March 18, 2026
Summary
This study introduces a hybrid machining process for Zinc Sulfide (ZnS) crystals, combining single-point diamond turning (SPDT) and vibration-assisted magnetorheological finishing (V-MRF). The method successfully achieves sub-nanometer precision, significantly reducing surface roughness and tool marks for advanced optical applications.
Area of Science:
- Materials Science
- Optical Engineering
- Manufacturing Technology
Background:
- Zinc Sulfide (ZnS) crystals are vital infrared optical materials, particularly for national defense.
- The inherent soft-brittle and polycrystalline nature of ZnS presents significant challenges for high-precision machining.
- Achieving sub-nanometer precision on ZnS surfaces is crucial for advanced optical component performance.
Purpose of the Study:
- To develop and validate a hybrid machining process for sub-nanometer precision polishing of ZnS crystals.
- To overcome the limitations of conventional machining methods in producing high-quality ZnS optical surfaces.
- To optimize process parameters for both single-point diamond turning (SPDT) and vibration-assisted magnetorheological finishing (V-MRF) stages.
Main Methods:
- A hybrid approach integrating single-point diamond turning (SPDT) for initial shaping and vibration-assisted magnetorheological finishing (V-MRF) for precision polishing.
- Optimization of process parameters for both SPDT and V-MRF to minimize surface roughness and eliminate periodic tool marks.
- Characterization of surface quality, including root mean square (RMS) roughness and tool mark amplitude, before and after V-MRF.
Main Results:
- SPDT processing resulted in a surface roughness of 1.327 nm RMS with tool mark amplitude below 2 nm.
- Subsequent V-MRF processing significantly improved surface quality, achieving a roughness of 0.887 nm RMS and tool mark amplitude below 0.9 nm.
- V-MRF processing reduced surface roughness by 33.15% and tool mark amplitude by 55% compared to the SPDT-processed surface.
Conclusions:
- The proposed hybrid SPDT and V-MRF process is effective for achieving sub-nanometer precision polishing of ZnS crystals.
- This combined approach successfully addresses the challenges posed by the material properties of ZnS, enabling high-quality optical surface fabrication.
- The optimized parameters and demonstrated results validate the hybrid process for critical infrared optical material applications.
