Processes, Vol. 14, Pages 84: Recent Advances in Hybrid Non-Conventional Assisted Ultra-High-Precision Single-Point Diamond Turning

Processes doi: 10.3390/pr14010084

Authors:
Shahrokh Hatefi
Yimesker Yihun
Farouk Smith

Ultra-precision single-point diamond turning (SPDT) remains the core process for fabricating optical-grade surfaces with nanometric roughness and sub-micrometer form accuracy. However, machining hard-to-cut or brittle materials such as high-entropy alloys, metals, ceramics, and semiconductors is limited by severe tool wear, high cutting forces, and brittle fracture. To overcome these challenges, a new generation of non-conventional assisted and hybrid SPDT platforms has emerged, integrating multiple physical fields, including mechanical, thermal, magnetic, chemical, or cryogenic methods, into the cutting zone. This review comprehensively summarizes recent advances in hybrid non-conventional assisted SPDT platforms that combine two or more assistive techniques such as ultrasonic vibration, laser heating, magnetic fields, plasma or gas shielding, ion implantation, and cryogenic cooling. The synergistic effects of these dual-field platforms markedly enhance machinability, suppress tool wear, and extend ductile-mode cutting windows, enabling direct ultra-precision machining of previously intractable materials. Recent key case studies are analyzed in terms of material response, surface integrity, tool life, and implementation complexity. Comparative analysis shows that hybrid SPDT can significantly reduce surface roughness, extend diamond tool life, and yield optical-quality finishes on hard-to-cut materials, including ferrous alloys, composites, and crystals. This review concludes by identifying major technical challenges and outlining future directions toward optimal hybrid SPDT platforms for next-generation ultra-precision manufacturing.

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Shahrokh Hatefi www.mdpi.com