Ultra-precision grinding of optical glasses using mono-layer nickel electroplated coarse-grained diamond wheels. Part 2: Investigation of profile and surface grinding

•Conditioned diamond wheels can be applied for ultraprecision grinding optical glasses.•In surface grinding of BK7 and Zerodur the sub-surface damage depth ranges 3–5μm.•In surface grinding BK7 the resulted surface roughness is around 1nm Ra.•The low wear rate of conditioned wheels guarantees a high surface form accuracy.•Huge potential for precision grinding large workpieces via conditioned diamond wheels. After finishing the precision conditioning of mono-layer nickel electroplated coarse-grained diamond wheels with 151μm (D151), 91μm (D91) and 46μm (D46) grain size, resp., profile and surface grinding experiments were carried out on a five-axis ultra-precision grinding machine with BK7, SF6 optical glasses and Zerodur glass ceramic. A piezoelectric dynamometer was used to measure the grinding forces, while an atomic force microscopy (AFM), white-light interferometer (WLI)) and scanning electron microscope (SEM) were used to characterize the ground surface quality in terms of micro-topography and subsurface damage. Moreover, the wear mechanics of the coarse-grained diamond wheels were analyzed and the grinding ratio was determined as well, in aiming to evaluate the grinding performance with the conditioned coarse-grained diamond wheels. Finally, the grinding results were compared with that of the fine-grained diamond wheels with regard to the ground specimen surface quality, process forces and wheel wear as a function of stock removal. The experimental results show that the precision conditioned coarse-grained diamond wheels can be applied in ductile mode grinding of optical glasses with high material removal rates, low wheel wear rates and no dressing requirement yielding excellent surface finishes with surface roughness in the nanometer range and subsurface damage in the micrometer range, demonstrating the feasibility and applicability of the newly developed diamond grinding technique for optical glasses.