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Advancement in technology has now made it possible to machine hard and brittle materials to a very close tolerance Ultra-precision machining has been developed, and a new machining concept known as ductile mode machining has been introduced Using this machine coupled with the ductile mode theory, a mirror-like finish can be achieved on the workpiece without the need to polish it [67] [66] In ductile mode machining, feeds and depth of the cut have to be very Fig 437: Roughness (Ra) of a polished aspheric glass surface small of the order of 10 nm and 1 m, versus the polishing time [64] [65]

The generic context diagram for a product or service (Fig. 5-1) includes the product or service we are creating in the large circle. The surrounding boxes are external systems or components with which our product or service is likely to interface. In a systems model such as a context diagram, people or groups of people are considered to be systems. Where appropriate, we identify communication between external systems. The curved lines between the system we are creating and each external system or component represent the data ows that will move between our system and each particular external system or component. If we fully de ne these data ows and their transmission requirements, we have speci ed all of the interface standards that our system must support in order to function properly. If your product or service has di erent customer groups, you create a box for each one, as they will have di erent inputs and outputs. There can also be many peripheral stakeholders, and many linked products or services. For example, as illustrated in Fig. 5-2, a computer program that we develop

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respectively [68] With the ultra-precision machine set-up, full ductile mode machining can be achieved, and the surface finish is mirror-like without the need to have subsequent processes such as polishing [67] [69] Most of the ultra-precision machines available in the market are equipped with machining systems that adopt either single-point diamond tools or multi-point abrasive (grinding) wheels However, in some cases, both machining systems can be incorporated into one machine on customer request for enabling both single- and multi-point abrasive machining operations Figure 438 shows a typical construction of both ultra-precision machines According to Chapman [69] and Schulz and Moriwaki [70], an ultra-precision machine is defined as a machine that has machining systems with the following movement accuracies: (i) slide geometric accuracy of less than 1 m (ii) spindle error motions of less than 50 nm (iii) control and feedback resolutions of less than 10 nm With the aforementioned movement accuracies, it is expected that the ultra-precision machine will be able to generate the following workpiece accuracies:

The basic concept of some products predicts their failure not because they don t work but because they don t make sense. Consider Mennen s vitamin E deodorant. That s right, you sprayed a vitamin under your arms. That doesn t make sense unless you want the healthiest, best-fed armpits in the nation. It quickly failed. Consider the Apple Newton. It was a fax, beeper, calendar keeper, and pen-based computer. Too complex. It s gone, and the much simpler iPhone is an enormous success. The best way to really enter minds that hate complexity and confusion is to oversimplify your message. Some of the most powerful programs are those that focus on a single word (Volvo: safety; BMW: driving). The lesson here is not to try to tell your entire story. Just focus on one powerful differentiating idea and drive it into your prospect s mind. That sudden hunch, that creative leap of the mind that sees in a flash how to solve a problem in a simple way, is something quite different from general intelligence. If there s any trick to finding that simple set

Fig 438: A typical construction of a (a) two-axis an ultra-precision single-point diamond turning machine [71],

for a company might have employees in one or more departments as the customers. Peripheral stakeholders would include people who got reports from the computer program, but did not actually use it, and also support personnel. And the linked products or services would be any computers running the program and any other programs that exchange data with the program we are making.

(b) four-axis an ultra-precision diamond grinding machine (Courtesy Toshiba Machine Co, Ltd)

Fig. 5-2.

(i) a dimensional accuracy in the range of some microns (ii) a surface form accuracy in the range of 100 nm or better (iii) a surface texture in the range of 5 nm or better

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