Freeform machining of hard materials is an important step in the fabrication of precision tooling. Precision tooling fabricated from materials like tungsten carbide can be used to replicate precision structures in difficult-tomachine materials like glass. The applications of this process are broad and include optics, biomedical sensors, and aerospace components. The two most common tooling materials are tungsten carbide and silicon carbide. These materials are preferred due to their high hardness and melting temperature; however, they are difficult to machine because mechanical cutting or shearing of the material results in unpredictable. Therefore precision, freeform machining of tungsten carbide and silicon carbide requires a grinding or polishing process. These approaches are not without complication though. Due to high wheel wear, suitable form accuracy and surface finish are difficult to achieve during freeform machining.
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