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Ultra-precision machining processes fall under the nanotechnology regime Ion beam machining, is a process that functions at the atomic level, is known to be an ultra-precision machining process This inert gas ion process employs argon ions or other inert gas ions such as Kr and Xe at high kinetic energy levels of the order of 10 KeV to bombard and erode the surface of the workpiece By these means, the parent atoms are ejected by collision and emission by a phenomenon known as the ion sputter The penetration depth of an ion at 1 KeV as estimated from electron diffraction patterns is about 5 m The method neither generates heat to an intolerable level since the material removed is in units of atoms and in a random manner nor does it cause any significant mechanical strain damage in the machined surface layer Some of the argon ions are retained, substituting displaced workpiece atoms This process has a machining resolution of about 10 nm The ion-beam milling process (Figure 130), which uses a DC discharge, is a good example of an energy beam machining process

At last we have something, an actual product or service, to show for all the work we have done At the end of the development stage, the team will deliver: A product or service that has been tested and meets the requirements speci cation and design speci cation, as modi ed by change control A nearly nal user manual or help system Technical speci cations to be used by future teams for support and modi cations, such as software code documentation and hardware technical speci cations designed to be used by future programmers and engineers who will support and modify the system A proposed nal support plan A proposed nal training plan A complete high-level and low-level test plan A test bed and test data les or test cases Documentation of all test results Documentation of any open issues A draft training plan.

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Fig 130: A model of the ion beam machining/sputtering process [1]

Of course, not all of these will be needed on every project In the design stage, we determined what products and services would be of value to the customer, and that is the actual, speci c list of outputs for the project you are managing As project managers, we will deliver: A plan for transition to production and deployment, covering all steps to be taken and the management of issues from all nine areas of knowledge A validated project overview, with any changes resulting from change control integrated The business case, with the cost budget and delivery dates validated through PERT estimation The project schedule, created by the WBS process and PERT, showing estimated vs actual results and incorporating project change, probably maintained in a project management software tool The project budget, in detail, with estimated vs actual results to date A risk plan for the remainder of the project.

As temperature variations can affect the accuracy of a process [20, 22], manufacturing engineers must pay attention to these variations when there is a need for accuracy and precision The thermal expansion of the components of a machine tool, which causes distortion, is an important factor that controls the precision of a machine tool The sources of heat may originate internally such as in bearings; machine ways, motors, and heat generated from the cutting zone, or may be external, such as from nearby furnaces, heaters, sunlight, and fluctuations in cutting and ambient temperature [6] The use of high-speed machining spindles with a coolant supply such as the one shown in Figure 131 is desirable [21] These considerations are particularly important in precision and ultra-precision machining, including diamond turning, where dimensional tolerances and surface finish have to necessarily be in the nanorange

Fig 131:

We may have one other set of deliverables: presentations or demonstrations of the system for the sponsor and the customers Since we have something to show for all of our work, we should show it!.

come a critical part of your marketing efforts. So here is a list of dos and don ts about this process.

A high-speed spindle with a coolant supply minimizes temperature variations [21]

Table 8-1

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