Sustainability of Methods for Augmented Ultra-Precision Machining

Optical-grade surfaces can be manufactured on metals and ceramics through precise control of diamond cutting tools in ultra-precision machining and traditional optimization of machining parameters. However, researchers have sought out innovative techniques that further improve precision manufacturing efficiency by reducing cutting forces, improving machined surface quality, and lowering tool wear. Many augmentations have been categorized as sustainable solutions simply based on the observation of reduced cutting forces, but an in-depth perspective of the actual energy savings is rarely provided. Thus, this review provides systematic evaluations of the actual energy consumed to implement these augmentations in comparison to the effective energy savings, which would justify the appropriate categorization of green technology. These augmentations include workpiece, tool, and process modifications that would serve as examples for future research to adopt this uncommon perspective of identifying the true significance of the reported results toward sustainable manufacturing. The article also proposes a three-tiered discussion for future research and development in this field, with the final objective of identifying optimal sustainable manufacturing methods with a well-supported theoretical foundation.