Creation of 3-D tiny statue by 5-axis control ultraprecision machining

The study deals with the creation of a 3-dimensional (3-D) complicated tiny statue by means of a 5-axis control ultraprecision machining center and a pseudo ball end mill of single crystal diamond. In recent years, 3-D microstructures are required to provide components for micromechanism as well as metal molds and dies. Thus, as an example of complicated 3-D microstructures, a Buddha head of 3 mm in size was created, based on the scanned data of an actual statue. A control program developed in the study enables a diamond tool to feed around the head and to move from the top of the head to the neck not only by 4-axis control but also by 5-axis control to prevent the tool and its holder from colliding with a workpiece. As a result, a tiny Buddha head could be created with high surface quality. (C) 2002 Elsevier Science Ltd. All rights reserved.