PATENT DOCUMENT

Publication Number: US-9545024-B2
Application Number: US-201213610838-A
Country: US
Kind Code: B2

Title: Diamond cutting tools

Abstract:
The embodiments described herein relate to methods, systems, and structures for cutting a part to form a highly reflective and smooth surface thereon. In some embodiments, the part includes substantially horizontal and vertical surfaces with edges and corners. In described embodiments, a diamond cutter is used to cut a surface of the part during a milling operation where the diamond cutter contacts the part a number of times with each rotation of the spindle of a milling machine. The diamond cutter has a cutting edge and a land. The cutting edge cuts the surface of the part and the land burnishes the surface of the part to form a highly reflective and smooth surface. Thus, the diamond cutter cuts and burnishes portions of the part, thereby eliminating a subsequent polishing step.

Claims:
What is claimed is: 
     
       1. A cutting tool assembly comprising:
 a holder configured to rotate about an axis; and 
 a cutting tool radially attached to the holder such that the cutting tool rotates about the axis during a cutting operation, the cutting tool comprising:
 a shank having a first end secured to the holder, and 
 a cutter attached to a second end of the shank opposite the first end, the cutter comprising a cutting edge, a heel and a land corresponding to a substantially flat surface between the cutting edge and the heel, wherein during the cutting operation the cutting edge and the land are substantially parallel to the axis, wherein the cutting edge cuts material from a workpiece to form a surface of the workpiece having peaks and troughs, and the land removes at least a portion of the peaks, thereby burnishing the surface of the workpiece, wherein a relative angle of the land with respect to the cutting edge is adjustable so as to control an amount of burnishing by the land. 
 
 
     
     
       2. The cutting tool assembly as recited in  claim 1 , wherein the heel engages with the surface of the workpiece during the cutting operation. 
     
     
       3. The cutting tool assembly as recited in  claim 1 , wherein a distance between successive peaks is proportionally related to a cutting radius, the cutting radius being a measurement from the axis to the cutting edge. 
     
     
       4. The cutting tool assembly as recited in  claim 1 , wherein the shank is in a substantially perpendicular orientation with respect to the axis during the cutting operation. 
     
     
       5. The cutting tool assembly as recited in  claim 1 , wherein the holder is configured to be positioned in a milling machine. 
     
     
       6. The cutting tool assembly as recited in  claim 5 , wherein the cutting tool is configured to cut the workpiece in an interrupted cutting operation wherein the cutting tool engages with and disengages from the workpiece a plurality of times. 
     
     
       7. The cutting tool assembly as recited in  claim 1 , wherein the shank and the cutter are attached using a braising procedure. 
     
     
       8. The cutting tool assembly as recited in  claim 1 , wherein the cutting tool assembly includes a plurality of cutting tools radially attached to the holder. 
     
     
       9. A method of cutting a workpiece using a cutting tool assembly, the cutting tool assembly comprising:
 a holder configured to rotate about an axis; and 
 a cutting tool radially attached to the holder, the cutting tool comprising:
 a shank having a first end secured to the holder, and 
 a cutter attached to a second end of the shank opposite the first end, the cutter comprising a cutting edge, a heel and a land disposed between the cutting edge and the heel, wherein the heel is recessed relative to the cutting edge with respect to a cutting arc of the cutter, wherein during a cutting operation: 
 the cutting edge and the land are substantially parallel to the axis, 
 the cutting tool rotates about the axis such that the cutting edge removes material from the workpiece to form peaks and troughs on a surface of the workpiece, and 
 the land removes at least a portion of the peaks, thereby smoothing the surface of the workpiece; and 
 wherein cutting the workpiece includes adjusting a relative angle of the land with respect to the cutting edge so as to control an amount of burnishing by the land. 
 
 
     
     
       10. The method as recited in  claim 9 , wherein a distance between successive peaks is proportionally related to a cutting radius, the cutting radius being a measurement from the axis to the cutting edge. 
     
     
       11. The method as recited in  claim 9 , wherein the heel engages with the surface of the workpiece during the cutting operation. 
     
     
       12. The method as recited in  claim 9 , wherein the cutter is comprised of diamond. 
     
     
       13. A cutting tool assembly comprising:
 a holder configured to rotate about an axis; and 
 a cutting tool radially attached to the holder, the cutting tool comprising:
 a shank having a first end secured to the holder, and 
 a cutter attached to a second end of the shank opposite the first end, the cutter comprising a cutting edge, a heel and a land disposed between the cutting edge and the heel, wherein the heel is recessed relative to the cutting edge with respect to a cutting arc of the cutter, and wherein a relative angle of the land with respect to the cutting edge is adjustable, wherein during a cutting operation: 
 the cutting edge and the land are substantially parallel to the axis, 
 the cutting tool rotates about the axis such that the cutting edge removes material from a workpiece to form peaks and troughs on a surface of the workpiece, and 
 the land removes at least a portion of the peaks, thereby smoothing the surface of the workpiece. 
 
 
     
     
       14. The cutting tool assembly as recited in  claim 13 , wherein cutting tool corresponds to a first cutting tool having a first shank and a first cutter, wherein the cutting tool assembly includes a second cutting tool having a second shank and a second cutter, the second cutter including a second cutting edge and a second land that are substantially parallel to the axis. 
     
     
       15. The cutting tool assembly as recited in  claim 13 , wherein the shank is in a substantially parallel orientation with respect to the axis during the cutting operation. 
     
     
       16. The cutting tool assembly as recited in  claim 13 , wherein the cutter is comprised of diamond. 
     
     
       17. The cutting tool assembly as recited in  claim 16 , wherein the cutter is comprised of a polycrystalline diamond or a mono crystalline diamond. 
     
     
       18. The cutting tool assembly as recited in  claim 13 , wherein the holder is cylindrical in shape.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 61/689,170, filed May 29, 2012, and entitled “COMPONENT FOR AN ELECTRONIC DEVICE,” which is incorporated herein by reference in its entirety and for all purposes. 
    
    
     FIELD OF THE DESCRIBED EMBODIMENTS 
     The described embodiments relate generally to cutting and to surface finishing. More specifically, methods and tools for cutting a highly reflective and smooth surface on a finished product. 
     BACKGROUND 
     Many consumer products such as electronic devices have surfaces that are fabricated from metal. In many cases, these metal surfaces are shiny and reflective so as to enhance the look and feel of the products. In general, the smoother the metal surface, the more reflective it is. These metal surfaces are often polished to rub or chemically reduce the amount of irregular topography of the metal surface to leave a smoother profile, and thus a shinier surface. 
     In some cases, the metal surfaces can include sharp edges and features. Since standard polishing techniques typically reduce the overall topography of the metal surface, these standard polishing techniques can also erode the sharp edges leaving rounded or tapered features. 
     Therefore, providing a device and method for producing a highly reflective metal surface while keeping the integrity of the workpiece geometry, especially at sharp edges, is desired. 
     SUMMARY 
     This paper describes various embodiments that relate to cutting and finishing a surface using a cutter capable of cutting and burnishing a surface. Methods described are useful for cutting and providing a highly reflective and smooth surface to a part, such as an enclosure for an electronic device. The cutting methods can be used to cut metal or non-metal surfaces. In some embodiments, methods involve cutting a part having substantially horizontal and vertical surfaces. For example, methods described can be used to cut chamfered portions along an edge of an enclosure for an electronic device. The highly reflective and smooth surface can then be provided a protective layer, such as an anodization layer. 
     In described embodiments, the cutter has a cutting edge, a heel and a land disposed between the cutting edge and heel. In some embodiments, the cutter is made of diamond material, such as mono crystalline diamond or poly crystalline diamond. The cutter can be used with a milling machine where the cutter contacts a workpiece a number of times with each rotation of the spindle of the milling machine. The cutting edge cuts the surface of the workpiece and the land burnishes the surface of the workpiece to form a highly reflective and smooth surface. In some embodiments the heel of the cutter can also burnish the surface of the workpiece. Thus, the cutter can cut and burnish portions of the workpiece in one operation, thereby eliminating a subsequent polishing step. 
     According to one embodiment, a cutting tool assembly is described. The cutting tool assembly includes a holder configured to rotate about an axis. The cutting tool assembly also includes a cutting tool radially attached to the holder. The cutting tool includes a shank having a first end secured to the holder. The cutting tool also includes a diamond cutter attached to a second end of the shank, the second end being opposite the first end. The diamond cutter includes a cutting edge, a heel and a land disposed between the cutting edge and heel. When the holder rotates about the axis, the cutting edge removes material from a workpiece to form a second surface having a number of peaks and troughs. The peaks reduce an overall reflectiveness and smoothness of the second surface. The land removes substantially all the peaks to form a third surface that is highly reflective and smooth. 
     According to another embodiment, a cutting tool system for cutting a highly reflective finish on a surface of a workpiece is described. The cutting tool system includes a milling machine having a spindle with an axis of rotation. The cutting tool system additionally includes a tool holder configured to rotate about an axis of rotation. The cutting tool system also includes a cutting tool radially and removably coupled to the tool holder. The cutting tool includes a shank having a first end secured to the tool holder. The cutting tool also includes a cutter attached to a second end of the shank. The second end is opposite the first end. The cutter includes a cutting edge, a heel and a land disposed between the cutting edge and heel. When the cutting tool rotates about the axis of rotation, the cutting edge removes material from a workpiece to form a second surface having the peaks and troughs. The peaks reduce an overall reflectiveness and smoothness of the second surface. The land removes substantially all the peaks to form a third surface that is highly reflective and smooth. 
     According to an additional embodiment, a method of calibrating a cutting tool system is described. The cutting tool system includes a milling machine having a spindle and a cutter removably coupled to the milling machine. The cutter has a cutting edge, a heel and a land disposed between the cutting edge and the heel. The calibration method involves positioning the cutter in the milling machine such that the cutting edge, heel and land are a radial distance from an axis of rotation of the spindle such that the cutter is positioned to cut a workpiece. The method also involves forming a reference line between the cutting edge and the axis. The method further involves measuring a first angle between the land and the reference line. The method additionally involves cutting a workpiece. The method also involves inspecting the workpiece to determine the reflectiveness and smoothness of a cut surface. The method additionally involves re-positioning the cutter within the milling machine such that the land is at a second angle from the reference line. The method further involves repeating the cutting, inspecting and re-positioning until a predetermined reflectiveness and smoothness of the cut piece is achieved. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a diamond cutting tool assembly in accordance with described embodiments. 
         FIGS. 2A and 2B  illustrate additional configurations of diamond cutting tool assemblies in accordance with described embodiments. 
         FIG. 3  illustrates two perspective side views of a diamond cutting tool in accordance with described embodiments. 
         FIGS. 4A and 4B  illustrate perspective side views of an insert and shank portions of a diamond cutting tool in accordance with described embodiments. 
         FIG. 5  illustrates a diamond cutter during a cutting procedure in accordance with described embodiments. 
         FIGS. 6A and 6B  illustrate a selected profile of a part undergoing a cutting procedure in accordance with described embodiments. 
         FIGS. 7A-7D  illustrate selected profiles of two separate parts undergoing cutting procedures using two different diamond cutting tools in accordance with described embodiments. 
         FIGS. 8A and 8B  illustrate diamond cutters undergoing two different alignment procedures in accordance with described embodiments. 
         FIG. 9  is a flowchart illustrating a process which includes a cutting process graphically presented in  FIGS. 10A-10D . 
         FIGS. 10A-10D  graphically illustrate selected profiles of a part undergoing a cutting process described in the flowchart of  FIG. 9 . 
         FIG. 11  is a schematic isometric view of a portable electronic device configured in accordance with an embodiment of the disclosure. 
         FIG. 12  is a schematic isometric view of at least a portion of a subassembly of the electronic device of  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION OF SELECTED EMBODIMENTS 
     The following disclosure describes various embodiments of electronic devices, such as portable electronic devices including, for example, mobile telephones. Certain details are set forth in the following description and Figures to provide a thorough understanding of various embodiments of the present technology. Moreover, various features, structures, and/or characteristics of the present technology can be combined in other suitable structures and environments. In other instances, well-known structures, materials, operations, and/or systems are not shown or described in detail in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the technology. Those of ordinary skill in the art will recognize, however, that the present technology can be practiced without one or more of the details set forth herein, or with other structures, methods, components, and so forth. 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     In the detailed description, reference is made to cutting a workpiece or part. In certain embodiments, the part can be made of metal, such as aluminum or aluminum alloy. However, a person of skill in the art would recognize that in the context of the present technology, the term part can refer to any suitable material capable of undergoing a cutting procedure to form a highly reflective surface, including metal, plastic, glass, and so forth. 
     The embodiments described herein relate to methods, systems, and structures for forming a highly reflective surface cut into a part. In the described embodiments, a diamond cutter is used to cut a surface of the part. The diamond cutter can be a poly crystalline diamond (PCD) or a mono crystalline diamond (MCD). In described embodiments, the diamond cutter has a cutting edge, a land and a heel. The cutting edge removes surface material from the surface of the part to form a second scalloped surface having peaks and troughs, the peaks reducing the overall reflective or smooth appearance of the second surface. The land, and optionally heel, subsequently burnishes the second surface by reducing the peaks to form a highly reflective and smooth finished surface. Thus, the diamond cutter simultaneously cuts and burnishes portions of the part, eliminated the need for an additional polishing step. In preferred embodiments, the diamond cutter is configured to have a relatively long cutting radius, which results in the smoother highly reflective finished surface. 
     In described embodiments, a diamond cutter is mounted in a machining tool, such as a computerized numerical control (CNC) machining tool, for cutting a part. In certain embodiments a diamond cutter is configured to be used in a milling machine, wherein the diamond cutter is rotated in a circular motion around a spindle axis and moved along the workpiece surface to contour the surface of the workpiece.  FIG. 1  shows a cutting tool assembly  100  in accordance with described embodiments. As shown, cutting tool assembly  100  includes tool holder  106  and cutting tool, which includes diamond cutter  102  and shank  104 . Diamond cutter  102  is coupled to shank  104  using, for example, a brazing procedure. Shank  104  is configured to removably fit into tool holder  106 , which is in turn configured to be positioned in a milling machine (not shown). Cutting tool assembly  100  is positioned to cut workpiece  108 , which can be secured using any of a number of suitable methods, such as by use of a clamp. During a cutting operation, cutting tool assembly  100  rotates about spindle axis  110  while secured workpiece  108  is moved toward diamond cutter  102 . In alternative embodiments, cutting tool assembly can be moved toward secured workpiece  108 . The cutting edge of diamond cutter  102  is positioned at a cutting radius  112  from the spindle axis  110 . With each rotation of the spindle, diamond cutter  102  takes a cut at the surface of workpiece  108 . During a milling cutting operation, the cutting edge of diamond cutter  102  enters and exits workpiece  108  a number of times, also known as interrupted cutting. This interrupted cutting can produce a scalloped surface on workpiece  108 , which can diminish the overall reflective or smooth appearance of the cut surface. The cutting tool and methods described herein can reduce the amount of scalloped surface on workpiece  108 , thereby forming a highly reflective and smooth finished surface on workpiece  108 . Details regarding reducing a scalloped surface in accordance with embodiments will be described below. 
       FIGS. 2A and 2B  illustrate additional configurations of cutting tool assemblies in accordance with described embodiments. At  FIG. 2A , diamond cutter  202  is coupled to shank  204 , which is in turn removably coupled to tool holder  206 . Tool holder  206  is configured to be mounted in a milling tool (not shown). In this case, shank  204  is positioned in tool holder  206  such that the length of shank  204  is substantially parallel to the spindle axis of rotation  210 . Workpiece  208  is positioned such that diamond cutter  202  can cut the surface if workpiece  208 . At  FIG. 2B , holder  212  is configured to hold two shanks  214  and  216 , each of which have diamond cutters  218  and  220 , respectively, disposed thereon. In this case, both shanks  214  and  216  are substantially perpendicular to spindle axis of rotation  226 . Diamond cutter  218  is positioned to cut workpiece  222  and diamond cutter  220  is positioned to cut workpiece  224 . In one embodiment, workpiece  222  and  224  are the same workpiece and diamond cutters  218  and  220  cut workpiece  222 / 224  at different times. For example, diamond cutter  218  can cut a first portion of workpiece  222 / 224 . Next, workpiece  222 / 224  can be re-positioned in front of diamond cutter  220  and diamond cutter  200  can cut a second portion of workpiece  222 / 224 . 
       FIG. 3  illustrates two perspective side views of a diamond cutting tool  300  in accordance with some embodiments of the disclosure. Cutting tool  300  includes shank  302  and diamond cutter  304 . Diamond cutter  304  is mechanically coupled to shank  302  using, for example, a brazing procedure. The brazing procedure typically uses an alloy filler metal, such as silver containing filler alloy. As shown, diamond cutter  304  is positioned on the end of cutting tool  300  such that cutting edge  306 , land  308  and optionally heel  310  can contact the workpiece during cutting. Shank  302  is preferably made from a rigid material, such as carbide, to rigidly maintain the position of cutting tool  300  during cutting, thereby allowing a smoother finished cut to be made. The shape of shank  302  can vary to maximize rigidity during the cutting procedure. The length of shank  302  can in part determine the cutting radius during cutting of a workpiece. Shank  402  can be configured to be mechanically coupled to a tool holder (not shown) which is attached to a spindle of a milling machine (not shown), which spins cutting tool  300  at high speeds. In certain embodiments, cutting tool  300  is positioned in a tool holder (not shown) such that the cutting radius is relatively large. By using a relatively large cutting radius, cuts made by cutting tool  300  can have relatively less scalloped portions, which will be discussed in detail below with reference to  FIGS. 7A-7D . As cutting tool  300  is held rigidly in place by shank  302  within a tool holder (not shown), the cutting angle relative to the workpiece can stay steady. 
       FIGS. 4A and 4B  illustrate alternative embodiments of a cutting tool in accordance with the present technology.  FIG. 4A  shows two perspective views of an insert piece  400 . Diamond cutter  402  is mechanically coupled to insert piece  400  at on end using, for example, a brazing procedure. The brazing procedure can use an alloy filler metal, such as silver containing filler alloy. Diamond cutter  402  is positioned on the end of insert piece  400  such that the heel, land and optionally heel can contact the workpiece during cutting.  FIG. 4B  shows shank  410  which can be connected to insert piece  400  using, for example, bolts to form the finished cutting tool. The cutting tool can then be inserted in the machining tool similarly to cutting tool  300  of  FIG. 3 . 
     As described above, embodiments of the disclosure involve the use of a diamond cutter which can be made of a polycrystalline diamond (PCD) or a mono crystalline diamond (MCD). In general, diamond is arranged in a cubic crystalline lattice system, in which carbon atoms are covalently bonded. The extremely high bond and lattice energy of diamond makes it extremely hard therefore a better cutting material than metals or carbides, for example. Two forms of diamond are polycrystalline diamond (PCD) and monocrystalline diamond (MCD). PCD is made up of many small individual crystals bound together with a binder material, such as a cobalt binder. Cutting tools made of PCD can have a somewhat serrated edge due to the boundaries where the individual crystals are bound together. PCD cutting tools are often described by the average size of the crystals, also called grain size, and type of binder. When a PCD is used to cut a surface, marks from the cutting edge can appear on the surface which correspond to the grain boundaries between the crystals. These marks typically appear as lines on the workpiece surface. In contrast MCD is one continuous crystal which does not have grain boundaries. Since MCD does not have grain boundaries, it does not leave grain boundary marks from the cutting edge as in the case with PCD. It should be noted, however, that in a milling operation, both PCD and MCD cutters can leave marks due to an interrupted cut during the milling process. As described above, an interrupted cut is due to the cutter contacting the workpiece surface at each rotation of the spindle. The interrupted cutting can leave a scalloped surface on the workpiece. 
     In order to lessen the scalloped portions of a cut surface and to produce a highly reflective and smooth finished surface, embodiments of the present disclosure include a diamond cutter having features graphically illustrated in  FIG. 5 . The top view and close up inset views illustrated in  FIG. 5  show diamond cutter  504  cutting workpiece  102 . Diamond cutter  504  includes three surfaces: rake face  514 ; land or primary clearance  506 ; and secondary clearance  508 . Diamond cutter  504  is mechanically coupled to a shank (not shown), which is in turn mechanically coupled to a toll holder (not shown), which is in turn mechanically coupled to a milling machine (not shown). Cutting edge  510  of diamond cutter  504  rotates around the spindle axis of the milling machine at a cutting arc  522 . Cutting arc  522  is a function of the cutting radius (e.g.,  112  of  FIG. 1 ) from the cutting edge  510  to the spindle axis (e.g.,  110  of  FIG. 1 ). Diamond cutter  504  can contact workpiece  502  at cutting edge  510 , land  506  and heel  512 . Since cutting edge  510 , land  506  and heel  512  can come into contact with workpiece  502  during cutting, it is advantageous for these surface to be substantially free of defects caused, for example, by a lapping or polishing procedure in the manufacturing process of the diamond cutter. In preferred embodiments, cutting edge  510 , land  506  and heel  512  have minimal visual imperfections such as lapping or polishing chips. In one embodiment for a MCD cutter, the cutting edge, land and heel have no visible imperfections at 500× magnification. In one embodiment for a PCD cutter, the cutting edge, land and heel have no visible imperfections at 100× magnification. It should be understood that lower or higher quality diamond cutters with greater or fewer imperfections can be used. Factors such as cost, availability and type of diamond cutters can be considered when determining the quality of diamond cutter used in a particular application. For example, an MCD cutter with a high quality cutting edge (e.g., very few visible imperfections) can be used in applications where the resultant cut surface is at a highly visible portion of an electronic device. A PCD cutter can be used, for example, in applications where the resultant cut surface can be slightly obscured by, for example, a dark anodizing film. 
     Before a cutting operation begins, diamond cutter  504  can be aligned such that the cutting edge  510  contacts workpiece  502  and effective primary clearance angle  518  puts land  506 , and optionally heel  512 , into contact with workpiece  502 . Example alignment procedures will be discussed in detail below with reference to  FIGS. 8A and 8B . During cutting, diamond cutter  104  proceeds in the travel direction as show in  FIG. 5 . First, cutting edge  510  cuts the surface of workpiece  502  resulting in a second surface with peaks and troughs. Next, land  506 , and optionally heel  512 , can come into contact with workpiece  502  burnishing the surface and removing substantially all the peaks of the second surface, thereby providing a highly reflective and smooth finished surface on workpiece  502 . The degree in which the peaks are removed depends on the amount of burnishing the land and heel impart on the surface. Details regarding removal of peaked portions of a scalloped surface in accordance with embodiments will be described below with reference to  FIGS. 6A and 6B . Since the surface is highly reflective and smooth, there is no need for a subsequent traditional polishing process. In this way an entire polishing step can be removed from the manufacturing process. Note that in some embodiments, the effective primary clearance can be backed off the surface of workpiece  502  a small amount before cutting begins. In this backed off configuration, portions of land  506  can still come into contact and burnish workpiece  502  due to elastic recovery of workpiece  502  material during the cutting process. Using the cutter in this backed off configuration can extend the lifetime of diamond cutter  504 . 
     As discussed above, after a cutting edge of a diamond cutter cuts the surface of a workpiece, a scalloped surface can remain on the workpiece. To illustrate this graphically, reference will now be made to  FIGS. 6A and 6B , which show cross sections of a surface of a workpiece undergoing a cutting procedure in accordance with described embodiments. In  FIG. 6A , workpiece  600  has undergone cutting from only the cutting edge ( 510  in  FIG. 5 ), leaving a second surface with peaks  604  and troughs  602 . Peaks  604  can be caused by interrupted cutting due to the milling process as described above. In  FIG. 6A , peaks  604  protrude a height  606  from trough  602 . In  FIG. 6B , workpiece  600  has been contacted by the land, and optionally heel, ( 506  and  512 , respectively, in  FIG. 5 ) reducing substantially all the height  606  of peaks  604 , leaving a highly reflective finished surface  608 . It is noted that there still can be remaining slightly protruding portions  610  on highly reflective and smooth finished surface  608 , depending on the amount of burnishing (i.e. amount of rubbing), however surface  608  is generally highly reflective and smoothed to a mirror shine and generally does not require further polishing. 
     In order to obtain as smooth as possible highly reflective and smooth finished surface, in some embodiments the cutting radius ( 112  of  FIG. 1 ) is relatively long. To illustrate graphically how the cutting radius effects the overall smoothness of the resulting surface, reference will now be made to  FIGS. 7A-7D  which show side views of two different workpieces undergoing cutting from two different diamond cutters in accordance with the described embodiments.  FIGS. 7A and 7B  show workpiece  700  undergoing a cutting procedure using an diamond cutter with a short cutting radius, and  FIGS. 7C and 7D  show workpiece  712  undergoing a cutting procedure using an diamond cutter with a long cutting radius. 
     At  FIG. 7A , workpiece  700  has undergone cutting from the cutting edge of a diamond cutter assembly having a short cutting radius. That is, the distance between the cutting edge and the spindle axis is relatively short. After only cutting edge cuts workpiece  700 , a second scalloped surface  708  with peaks  704  and troughs  702  is formed. Peaks  704  can be caused by the interrupted cutting due to milling process. The distance  706  between the peaks  704  is directly proportional to the cutting radius of the diamond cutting assembly. At  FIG. 7B , workpiece  700  has been contacted by the land, and optionally the heel, reducing substantially all the height  722  of peaks  704 , leaving a highly reflective and smooth finished surface  709  with remaining slightly protruding portions  710  which diminish the overall reflective and smooth appearance of a highly reflective and smooth finished surface  709 . 
     At  FIG. 7C , workpiece  712  has undergone cutting from the cutting edge of a diamond cutter assembly having a short cutting radius. That is, the distance between the cutting edge and the spindle axis is relatively long. After only cutting edge cuts workpiece  712 , a second scalloped surface  720  with peaks  716  and troughs  714  is formed. Since the distance  718  between the peaks  716  is directly proportional to the cutting radius of the diamond cutting assembly, distance  718  is longer than distance  706  of workpiece  700  at  FIG. 7A . Thus, second surface  720  has a smaller portion having peak  716  compared to the second surface  708  of  FIG. 7A . At  FIG. 7D , workpiece  712  has been contacted by the land, and optionally the heel, reducing substantially all the height  724  of peaks  716 , leaving a highly reflective and smooth finished surface  720  with remaining slightly protruding portions  722 . Note that there are less remaining slightly protruding portions  722  in the highly reflective and smooth surface  720  compared to remaining slightly protruding portions  712  in the highly reflective and smooth surface  721 . Therefore, using a diamond cutter assembly having a longer cutting radius can provide an improved overall highly reflective and smooth finished surface. In one embodiment the diamond cutter assembly has a cutting radius about 35 millimeters. 
     Since the cutting procedures described in the present technology requires a high level of accuracy regarding the surface geometry of the workpiece, the cutting tool should be aligned at a high level of accuracy relative to the workpiece surface before the cutting process begins. It can be difficult to manufacture diamond cutter to meet extremely high levels of specified dimensional and defect free specifications. Therefore, embodiments of the disclosure involve calibration procedures to compensate for any imperfections in the geometric dimensions of the diamond cutter. In one embodiment, calibration involves calibrating the cutter directly on the workpiece surface wherein the cutter is rotated until the cutting edge, land and heel ( 510 ,  506  and  512 , respectively, in  FIG. 5 ) contact the workpiece surface. In other embodiments, calibration involves rotating the cutter tool until the land ( 506  in  FIG. 5 ) provides sufficient burnishing to the workpiece surface. 
       FIGS. 8A and 8B  illustrate two different alignment or calibration procedures to optimize the amount and effectiveness of burnishing in accordance with described embodiments. In both  FIGS. 8A and 8B , the diamond cutter is initially positioned in the milling machine for cutting. At  FIG. 8A , diamond cutter  802  is calibrated by controlling the difference in length between first line  804  from spindle axis  808  to cutting edge  810 , and a second line  812  from spindle axis  808  to heel  818 . The length of first line  804  (R 1 ) is measured and the length of second line  812  (R 2 ) is measured. Measurement can be accomplished by using, for example, laser generated reference lines (shown by dotted lines). Next, a cutting operation is performed on a workpiece (not shown) using the R 1  and R 2  parameters. After the cutting operation is complete, the workpiece is inspected to determine the quality of cut, i.e., the reflectiveness and smoothness of the resulting cut surface. Next, the position of diamond cutter  802  is moved such that R 1  is longer or shorter, i.e., land  814  and heel  818  are farther or closer to cutting arc  816 . The bigger R 2  is compared to R 1 , the more land  814  and heel  818  will rub the workpiece and the more burnishing the workpiece will experience. In this way, controlling the difference between R 1  and R 2  can control the amount of burnishing. In preferred embodiments, the difference between R 1  and R 2  are optimized to allow land  814  and/or heel  818  to sufficiently burnish the surface of the workpiece, but not rub so hard as to provide too much friction during cutting. Next, another cutting operation is performed and the workpiece is again inspected for quality of cut. If the quality of cut is not of an acceptable quality, the re-positioning of the diamond cutter  802 , cutting and inspecting is repeated until an acceptable quality cut is achieved. 
     At  FIG. 8B , diamond cutter  820  is positioned within the tool holder (not shown) by controlling the angle between reference line  822  from cutting edge  824  to spindle axis  832  and the land  826 . Reference line  822  can be generated by using, for example, a laser generated line (shown by dotted line). Next, a cutting operation is performed on a workpiece (not shown) using a theta angle  834  parameter. After the cutting operation is complete, the workpiece is inspected to determine the quality of cut, i.e., the reflectiveness and smoothness of the resulting cut surface. Next, the position of diamond cutter  820  is moved such that theta  834  is larger or smaller, i.e., land  826  and heel  828  are farther or closer to cutting arc  830 . The farther outside land  826  and heel  828  are to arc  830 , the more land  826  and heel  828  will rub the workpiece and the more burnishing the workpiece will experience. In this way, controlling the angle theta can control the amount of burnishing. As with the alignment procedure shown in  FIG. 8A , theta angle parameter  834  can be optimized to allow land  826  and heel  828  to sufficiently burnish the surface of the workpiece, but not rub so hard as to provide too much friction during cutting. As with the alignment procedure described for  FIG. 8A  above, the cutting, re-positioning and inspection can be repeated until an acceptable quality of cut is achieved. 
     During the alignment procedures shown in  FIGS. 8A and 8B , in some embodiments the amount of burnishing can be backed off the cutting radius a small amount before cutting begins. As discussed above with reference to  FIG. 5 , use of the diamond cutter in a backed off configuration can extend the lifetime of diamond cutter. In this backed off configuration prior to cutting, the heel does not touch the workpiece. However, during cutting the land can still come into contact with and burnish the surface of the workpiece due to elastic recovery of the workpiece material. Factors such as diamond cutter lifetime, desired amount of burnishing and amount of diamond cutter friction on the workpiece can be considered when optimizing the alignment of the cutting tool. 
     In described embodiments, the part can be cut at a substantially flat surface portion of the part wherein the substantially flat surface is given a highly reflective and smooth finish. Alternatively, the part can be cut at a portion of the part that has a feature with horizontal, vertical and angled surfaces. The diamond cutter can cut the feature to form a different feature that has a highly reflective and smooth finished surface. For instance, a chamfer may be cut at a corner or edge of a workpiece. The resulting chamfer will have a highly reflective and smooth finished surface in accordance with the described embodiments. In order to protect the highly reflective and smooth surface, an optional transparent coating or plating can be formed thereon. In certain embodiments, the transparent coating is an anodization layer that is substantially clear, thereby allowing the highly reflective surface to be visible through the anodization layer.  FIGS. 9 and 10A-10D  illustrate steps involved in a process of forming a feature with a highly reflective and smooth surface into a part in accordance with embodiments of the technology.  FIG. 9  is a flowchart detailing process steps and  FIGS. 10A-10D  graphically present side views of a portion of a metal part undergoing the process described in  FIG. 9 . In the following narrative, reference will be made to the flowchart of  FIG. 9  in conjunction with the side view presentations of  FIGS. 10A-10D . 
     Process  900  begins at  902  (corresponding to  FIG. 10A ) where part  1000  is cut to have a first surface with vertical  1002  and horizontal  1004  portions. In  FIG. 10A , the first surface has an edge  1006 . Part  1000  can be cut using any number of suitable cutting procedures such as a machining procedure to form the shape of part  1000 . It should be noted that substantially vertical  1002  and a horizontal  1004  portions in  FIG. 10A-10D  can form a edge  1006  having any angle, including a 90 degree angle. In addition, vertical  1002  and a horizontal  1004  portions can be substantially flat or they may be curved. The part can then undergo optional surface treatments such as polishing and/or addition of artwork (e.g., company logo and/or text) using, for example, a photolithography process. In one embodiment, a blasting operation can be performed whereby the part is exposed to blasting media to create a rough blasted surface over the part. 
     At  904  (corresponding to  FIG. 10B ), part  1000  undergoes an optional first anodization process to form a first anodization layer  1008  that covers at least portions of vertical  1002  and horizontal  1004  surfaces of part  1000  near edge  1006 . Anodization layer  1008  serves to protect the metal surface of part  1000  from corrosion and scratching. In one embodiment, first anodization layer  1008  is approximately 8 to 12 microns thick and is substantially opaque so that the underlying metal of part  1000  is not substantially visible through first anodization layer  1008 . Note that due to stress build up at edge  1006 , first anodization layer  1008  can have cracks  1010 . 
     At  906  (corresponding to  FIG. 10C ), a portion of the optional first anodization layer  1008  and a portion of metal part  1000  is cut using an diamond cutter described above to form a second surface  1012  which is highly reflective and smooth surface. In certain embodiments, a portion of the optional first anodization layer  1008  and a portion of metal part  1000  are given a rough cut using a different cutting tool prior to using a diamond cutter tool. The rough cut can be made so as to remove a bulk amount of material before diamond cutter is used in accordance with described embodiments. The rough cut can be made using a suitable cutting tool such as a carbide or a metal cutter or a diamond cutter of lesser quality than the diamond cutter used to cut a highly reflective and smooth surface as described above. In  FIG. 10C , the second surface is a chamfer. It should be noted that second surface  1012  can be cut at any angle relative to the horizontal  1004  and vertical  1002  portions. For example, second surface  1012  can be cut at a 45 degree angle relative to one of horizontal  1004  and vertical  1002  portions. Since second surface  1012  has a highly reflective and smooth surface, there is no need for subsequent polishing. This is advantageous, not only because it removes an extra step in the process, but also because traditional polishing techniques such as mechanical and chemical polishing, can erode features of the part. In particular, traditional polishing techniques can erode and round off sharp edges and corners such as the edges of chamfer  1012 , reducing the aesthetic appeal of the part. 
     At  908  (corresponding to  FIG. 10D ), part  1000  undergoes an optional second anodization process to form a second anodization layer  1014  substantially only on and to protect the highly reflective and smooth chamfer  1014 . It should be noted that the second anodization process can use different process parameters than the first anodization process described previously, forming second anodization layer  1014  with different physical characteristics than first anodization layer  1008 . For example, second anodization layer  1014  can be substantially transparent in order to allow the underlying highly reflective and smooth chamfer  1015  to be viewable. In addition, the second anodization layer  1014  can be formed such that there is a clearly defined interface between first anodization layer  1008  and second anodization layer  1014  (shown by an angle in  FIG. 10D ). After process  900  is complete, the finished part in  FIG. 10D  has a highly reflective and smooth chamfer  1012  with sharply defined and cosmetically appealing edges. 
     As discussed previously, tools and methods of the described embodiments can be applied in the fabrication of electronic devices, including for example, personal computers and portable tablets and phones.  FIG. 11  is a schematic isometric view of a portable electronic device  10  (“electronic device  10 ”), such as a mobile telephone, configured in accordance with an embodiment of the disclosure. In the illustrated embodiment, the electronic device  10  includes a body  11  carrying a display  12  that allows a user to interact with or control the electronic device  10 . For example, the display  12  includes a cover or cover glass  14  that is operably coupled to a frame, housing, or enclosure  16 . In certain embodiments, the display  12  and/or cover glass  14  can include touch sensitive features to receive input commands from a user. Moreover, in certain embodiments a cover or cover glass can be positioned on one side of the electronic device  10 , or a cover or cover glass can be positioned on opposing sides of the electronic device  10 . As described in detail below, the enclosure  16  and the cover glass  14  at least partially house or enclose several internal features of the electronic device. 
     In the embodiment illustrated in  FIG. 11 , the enclosure  16  also at least partially defines several additional features of the electronic device  10 . More specifically, the enclosure  16  can include audible speaker outlets  18 , a connector opening  20 , an audio jack opening  22 , a card opening  24  (e.g., SIM card opening), a front facing camera  24 , a rear facing camera (not shown), a power button (not shown), and one or more volume buttons (not shown). Although  FIG. 11  schematically illustrates several of these features, one of ordinary skill in the art will appreciate that the relative size and location of these features can vary. 
     In certain embodiments, the enclosure  16  can be made from a metallic material. For example, the enclosure  16  can be made from Aluminum, such as 6063 Aluminum. In other embodiments, however, the enclosure  16  can be made from other suitable metals or alloys. According to additional features of the embodiment shown in  FIG. 11 , the enclosure  16  includes opposing edge portions  30  (identified individually as a first edge portion  30   a  and a second edge portion  30   b ) extending around a periphery of the body  11 . In certain embodiments, one or both of the edge portions  30  can have a chamfered or beveled profile. As described in detail below, the chamfered edge portions  30  can be processed relative to the enclosure  16  to provide an aesthetically appealing appearance. For example, the exterior surface of the enclosure  16  can be treated and the edge portions  30  can subsequently be treated. In one embodiment, for example, a first anodization process can be applied to the enclosure  16  and a second subsequent anodization process can be applied to the edge portions  30 . Additional suitable surface treatments, including intermediary surface treatments, can be applied to the enclosure  16  and/or the edge portions  30 . In still further embodiments, the edge portions  30  can have other suitable profiles or shapes including and/or surface treatments. 
       FIG. 12  is a schematic isometric view of at least a portion of a subassembly  40  of the electronic device of  FIG. 11 . In the embodiment illustrated in  FIG. 12 , the subassembly  40  includes the enclosure  16  coupled to a cover glass, such as the cover glass  14  shown in  FIG. 11 . As shown in  FIG. 12 , the enclosure  16  includes a first enclosure portion  42  coupled to a second enclosure portion  44 , which is in turn coupled to a third enclosure portion  46 . More specifically, the enclosure  16  includes a first connector portion  48  that couples the first enclosure portion  42  to the second enclosure portion  44 . The enclosure also includes a second connector portion  50  that couples the second enclosure portion  44  to the third enclosure portion  46 . In certain embodiments, the first, second, and third enclosure portions  42 ,  44 , and  46  can be metallic and the first and second connector portions  48 ,  50  can be made from one or more plastic materials. As described below in detail, for example, each of the first and second connector portions  48 ,  50  can be formed from a two shot plastic process that includes a first plastic portion that joins the corresponding enclosure portions and a second cosmetic plastic portion that at least partially covers the first plastic portions. As further described in detail below, these plastic portions can be configured to withstand harsh manufacturing processes and chemicals that may be used to form and process the enclosure. In further embodiments, the enclosure portions  42 ,  44 , and  46  and/or the connecting portions  48 ,  50  can be made from other suitable materials including metallic, plastic, and other suitable materials. 
     According to additional features of the embodiment illustrated in  FIG. 10 , the enclosure  16  can include one or more low resistance conductive portions  52  (shown schematically) for grounding purposes. Conductive portions  52  can include, for example, of aluminum which can shield RF waves. The conductive portion  52  can be formed by removing one or more layers or portions of the enclosure  16  to provide a lower resistance through the enclosure  16  for antenna transmissions or communications. In certain embodiments, for example, the conductive portion  52  can be formed by laser etching or otherwise removing or etching an anodized portion of the enclosure  16 . 
     The illustrated subassembly  40  also includes several inserts  54  that provide increased structural connection strength relative to the enclosure  16 . In embodiments where the enclosure  16  is formed from Aluminum, for example, the inserts  54  can provide increased strength and durability. More specifically, in certain embodiments the inserts  54  can include titanium threaded inserts or nuts that are configured to threadably engage a corresponding fastener. Titanium inserts  54  can be advantageous in that the titanium material can withstand harsh manufacturing processes and chemicals. In other embodiments, however, the inserts  54  can be made from other suitable materials including, for example, steel, brass, etc. 
     According to yet additional features of the subassembly  40  shown in  FIG. 12 , and as described in detail below, the cover glass  14  can be securely coupled and/or offset (if desired) relative to the enclosure  16 . More specifically, the cover glass  14  can be aligned with a reference plane or datum relative to the enclosure  16 , and the enclosure  16  (and more specifically the first enclosure portion  42 , the second enclosure portion  44 , and/or the third enclosure portion  46 ) can include one or more access opening  56  to urge or bias the cover glass  14  relative to the enclosure  16  for secure attachment (e.g., adhesive attachment) while maintaining relatively tight tolerances between the coupled portions. 
     According to additional embodiments of the disclosure, and as described in detail below, the cover glass  14  can be made from a glass, ceramic, and/or glass-ceramic material. In one embodiment, for example, the cover glass  14  can be made from a glass with specific portions or volumes of the glass formed with ceramic properties. In other embodiments, however, the cover glass  14  can be formed from alumina silica based pigmented glass. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20120911
Publication Date: 20170110
Grant Date: 20170110
Priority Date: 20120529
Inventors: TAN NAPTHANEAL Y.
HUANG CHIEN-MING
LEE LONG HIN
GUOJIN LU
YUNDI YU
PENG LV
YIFENG YU
CHENDONG WU
ZE SHI
Assignee: APPLE INC
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