Al6061 surface roughness and optical reflectance when machined by single point diamond turning at a low feed rate

Ultra-precision face turning of Al6061 mirrors using single point diamond turning (SPDT) was undertaken to investigate the correlation between the surface roughness and reflectance. By reducing the feed rate, the optimal feed rate when the chip formation became unstable was studied. Most importantly, the impact on the roughness and reflectance was examined when the chip formation ceased to be continuous. It was determined that for a feed rate below 3 mm/min, the surface roughness always improved as the feed rate decreased, at the cost of a reduction of the normalized reflectance. The reduction of reflectance was determined to be the result of the lower material removal rates that led to a discontinuous chip formation.