"Doctoral thesis accepted by National University of Singapore, Singapore."

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880-01 Supervisor's Foreword; Parts of this thesis have been published in the following journal articles/chapters from various books:D.W.K. Neo, A.S. Kumar and M. Rahman, 'CAx technologies for hybrid fast tool/slow slide servo diamond turning of freeform surface', Proceedings of the Institution of Mechanical Engineers, Part B, J. Engineering Manufacture (2016) 230(8): 1465-1479D.W.K. Neo, A.S. Kumar and M. Rahman, 'Automated Guilloche machining technique for the fabrication of polygonal Fresnel lens array', Precision Enginee; Acknowledgements; Contents; Acronyms; Symbols; Summary; 1 Introduction.

1.1 Hybrid Freeform Surfaces1.2 Ultraprecision Machining of Hybrid Freeform Surfaces; 1.3 Main Objectives of This Dissertation; 1.4 Organization of This Dissertation; References; 2 Literature Review; 2.1 Multiple-Axis Ultraprecision Diamond Machining Techniques; 2.1.1 Fast Tool Servo (FTS); 2.1.2 Slow Slide Servo (SSS); 2.1.3 Other Multiple-Axis Ultraprecision Machining Techniques; 2.2 State-of-Art CAD/CAM/CAE Technologies; 2.2.1 CAD/CAM Technology for Surface Generation; 2.2.2 Surface Accuracy and Error Compensation Approaches; 2.3 Concluding Remarks; References.

3 Initial Development of CAD/CAM Technologies3.1 CAD/CAM for Multiple-Axis Ultraprecision Machining Processes; 3.1.1 Non-uniform Rational B-Spline Freeform Surfaces; 3.1.2 CAD/CAM Interpolator for FTS/SSS Diamond Turning; 3.2 API Methodology for CAD/CAM Software Development; 3.2.1 Experimental Validation; 3.3 Concluding Remarks; References; 4 Development of Hybrid FTS/SSS Diamond Turning; 4.1 Principle of Layered Tool Trajectory; 4.2 Layered Tool Trajectory Control; 4.3 Experimental Validations; 4.4 Concluding Remarks; References; 5 Novel Surface Generation of Complex Hybrid Freeform Surfaces.

6.2.2 Cutting Experiments and Results6.3 Concluding Remarks; References; 7 Integration and Implementation; 7.1 Integrated CAD/CAM System; 7.1.1 Integrated Sub-system for AGMT Process; 7.1.2 Integrated Sub-system for Diamond Turning Process; 7.1.3 Optimization of Tool Geometry; 7.1.4 Geometrical Splitting of Hybrid Freeform Surface; 7.2 Case Study 1: Hexagonal Fresnel Lens Array Using AGMT Process; 7.2.1 Experimental Validations; 7.2.1.1 Critical Machining Parameters for AGMT Process; 7.2.1.2 Cutting Experiments and Results; 7.3 Case Study 2: Multiple-Compound Eye Surface Design-B.

This thesis focuses on producing hybrid freeform surfaces using an advanced diamond-turning process, understanding the generation of surface accuracies (form errors) and how the choice of cutting strategies affects these, as well as simplifying the complications of generating cutting paths for such freeform surfaces. The breakthroughs behind this thesis are the development of novel, multiple-axis, diamond turning techniques to overcome the limitations of conventional diamond turning processes, an analytical model to optimize the generation of ultraprecise freeform surfaces, and an add-on tool path processor for CAD/CAM software solutions. It appeals to researchers and scholars with a strong machining background who are interested in the field of manufacturing ultraprecise freeform surfaces or in the field of optimizing ultraprecision machining processes.