Grinding of additively manufactured silicon carbide surfaces for optical applications

Horvath, Nick; Honeycutt, Andrew; Davies, Matthew A.

doi:10.1016/j.cirp.2020.04.079

Cited by 19 publications

(9 citation statements)

References 11 publications

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“…According to the available literature 9,19 , conventional machines cannot produce SiC optical finishing, but the results obtained in this work are compatible with the ones obtained in ultra-precision equipment 1,6,7 .…”

Section: Step 3: Grinding and Polishing Of α-Sic And β-Sic Workpieces...supporting

confidence: 85%

“…Due to extreme hardness and brittleness, material removal rates for SiC are very low, around 1/35 th that of fused silica and less than 1/50 th that of Zerodur 1 . Different techniques and technologies 1,3,5 have been used to produce SiC substrates close to the final dimension in order to reduce their post-processing, due to the complexity of the finishing process, generally carried out by diamond wheel grinding in expensive ultra-precise machines [6][7][8][9] . In ceramics grinding, the process of material removal by brittle fracture predominates 10 .…”

Section: Introductionmentioning

confidence: 99%

“…Workpieces with low roughness (Ra < 10 nm) and optical figure quality in the range λ/4 -λ/10 are obtained. On the other hand, the high-cost effectiveness is still prohibitive to fully realizing the ceramic's potential 7,17,21 .…”

Section: Introductionmentioning

confidence: 99%

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High-quality Finishing Process for Silicon Carbide Optical Components Using Conventional Equipment

2022

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The development of low-cost high quality surface finishing methods for silicon carbide (SiC) is an arduous task. Nowadays, the SiC mirrors manufacture involves extensive, complex, and costly finishing processes carried out on highly expensive ultra-precise machines. In this work, a cost-effective surface finishing method has been successfully developed, using conventional machines for the optical finishing of SiC. The results showed that the combination of ductile grinding and polishing in conventional low-cost machines allowed to obtain high-quality surface finish on SiC substrates with low roughness (4 -10 nm Ra ) and optical figure in the range λ / 4 -λ / 8, at a reduced 32 hours total processing time.

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Section: Step 3: Grinding and Polishing Of α-Sic And β-Sic Workpieces...supporting

confidence: 85%

Section: Introductionmentioning

confidence: 99%

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High-quality Finishing Process for Silicon Carbide Optical Components Using Conventional Equipment

2022

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“…Ceramics such as silicon carbide (SiC) have recently been implemented for optical applications with the added benefit of superior material properties over metals [7]. SiC has excellent physical, thermal, and mechanical properties, making it attractive for engineering applications such as heat exchangers, high-temperature seals and valves, armor, mirrors and optics, and electronics.…”

Section: Introductionmentioning

confidence: 99%

Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining

Dvorak

Gilmer

Zameroski

et al. 2023

JMMP

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This paper describes a hybrid manufacturing approach for silicon carbide (SiC) freeform surfaces using binder jet additive manufacturing (BJAM) to print the preform and machining to obtain the design geometry. Although additive manufacturing (AM) techniques such as BJAM allow for the fabrication of complex geometries, additional machining or grinding is often required to achieve the desired surface finish and shape. Hybrid manufacturing has been shown to provide an effective solution. However, hybrid manufacturing also has its own challenges, depending on the combination of processes. For example, when the subtractive and additive manufacturing steps are performed sequentially on separate systems, it is necessary to define a common coordinate system for part transfer. This can be difficult because AM preforms do not inherently contain features that can serve as datums. Additionally, it is important to confirm that the intended final geometry is contained within the AM preform. The approach described here addresses these challenges by using structured light scanning to create a stock model for machining. Results show that a freeform surface was machined with approximately 70 µm of maximum deviation from that which was planned.

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“…According to [1][2][3][4], the process of additive manufacturing (AM) is the method of material joining to produce a 3D object from digital data, generally layer upon layer. The most frequently used synonyms: additive layer manufacturing, additive processes, freeform fabrication [5]. This approach is the complete opposite of subtractive manufacturing, where for making parts, the material removes from the bulk substantial by grinding, milling, drilling, or carving.…”

Section: Introductionmentioning

confidence: 99%

Digital Modeling Accuracy of Direct Metal Laser Sintering Process

Dmitriyev

Manakov

2020

Eurasian Chem. Tech. J.

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Products obtained by metal additive manufacturing have exceptional strength properties that can be compared with forged parts, and in some cases, even surpass them. Also, the cost and time of parts manufacture are reduced by two or even three times. Because of this, today’s leading corporations in the field of aerospace industry introducing this technology to its production. To avoid loss of funds and time, the processes of additive manufacturing should be predictable. Simufact Additive is specialized software for additive manufacturing process simulation is dedicated to solving critical issues with metal 3D printing, including significantly reducing distortion; minimize residual stress to avoid failures; optimize the build-up orientation and the support structures. It also enables us to compare simulated parts with the printed sample or measure it as a reference. In other words, the simulated deformations can be estimated concerning the reference geometry. The current work aims to study the deformation of the sample during the Direct Metal Laser Sintering (DMLS) process made from Maraging Steel MS1. Simufact Additive software was used to simulate the printing process. The main idea is to compare the results of the simulation and the real model. EOS M290 metal 3D printer was used to make a test specimen.

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Grinding of additively manufactured silicon carbide surfaces for optical applications

Cited by 19 publications

References 11 publications

High-quality Finishing Process for Silicon Carbide Optical Components Using Conventional Equipment

High-quality Finishing Process for Silicon Carbide Optical Components Using Conventional Equipment

Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining

Digital Modeling Accuracy of Direct Metal Laser Sintering Process

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