Simulation and experimental study on form-preserving capability of bonnet polishing for complex freeform surfaces

Su, Xing; Ji, Peng; Jin, Yuan; Li, Duo; Walker, David D.; Yu, Guoyu; Li, Hongyu; Wang, Bo

doi:10.1016/j.precisioneng.2019.07.010

Cited by 26 publications

(9 citation statements)

References 28 publications

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“…As shown in Table 1 , from the current optical processing methods, small tool polishing is usually accompanied by large contact stress, and it is not applicable to the processing of light weight films [ 12 , 13 ]. However, the non-contact processing methods represented by magnetorheology and ion beam have a small volume of removal function and extremely low processing efficiency for optical component substrates [ 14 , 15 ].…”

Section: Introductionmentioning

confidence: 99%

The Tailored Material Removal Distribution on Polyimide Membrane Can Be Obtained by Introducing Additional Electrodes

et al. 2023

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Reactive ion etching (RIE) is a promising material removal method for processing membrane diffractive optical elements and fabrication of meter-scale aperture optical substrates because of its high-efficiency parallel processing and low surface damage. However, the non-uniformity of the etching rate in the existing RIE technology will obviously reduce the machining accuracy of diffractive elements, deteriorate the diffraction efficiency and weaken the surface convergence rate of optical substrates. In the etching process of the polyimide (PI) membrane, additional electrodes were introduced for the first time to achieve the modulation of the plasma sheath properties on the same spatial surface, thus changing the etch rate distribution. Using the additional electrode, a periodic profile structure similar to the additional electrode was successfully processed on the surface of a 200-mm diameter PI membrane substrate by a single etching iteration. By combining etching experiments with plasma discharge simulations, it is demonstrated that additional electrodes can affect the material removal distribution, and the reasons for this are analyzed and discussed. This work demonstrates the feasibility of etching rate distribution modulation based on additional electrodes, and lays a foundation for realizing tailored material removal distribution and improving etching uniformity in the future.

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Section: Introductionmentioning

confidence: 99%

The Tailored Material Removal Distribution on Polyimide Membrane Can Be Obtained by Introducing Additional Electrodes

et al. 2023

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“…The main body uses an elastic rubber sacculus (the interior is filled with constant pressure gas, and the air pressure is used as the grinding force), and hard grains are attached to the surface. During the grinding process, the elastic sacculus is deformed by force to fit the workpiece’s curved surface, and grains on the surface are squeezed to remove the workpiece material [ 10 , 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation on Surface Integrity of Nodular Cast Iron QT700-2 in Shape Adaptive Grinding

Zhao

Zhang

et al. 2023

Micromachines

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Nodular cast iron QT700-2 is extensively used in automobile engine crankshaft parts due to its prime mechanical properties. The journal of a crankshaft is a curved surface, and traditional wheel grinding easily causes grinding burn and surface and subsurface damage. Shape adaptive grinding (SAG) is a flexible grinding technology, which has the advantages of low grinding force and temperature, and good grinding quality. It is suitable for machining curved surface parts with complex shapes. Therefore, the SAG surface integrity of nodular cast iron QT700-2 was experimentally investigated. The influence of grinding parameters on grinding force, material removal rate, grinding temperature, and surface integrity was studied, and the machining performance of SAG tools was evaluated. It was concluded that the grain size in SAG is the most important factor affecting the grinding force, material removal rate, and surface roughness; the influence of SAG grinding is very weak, mainly removing the workpiece material. Then, the influence law of SAG technology on the surface integrity of nodular cast iron QT700-2 was summarized, and the optimal grinding parameters were obtained, providing a reference for the curved surface grinding of nodular cast iron QT700-2 in the future.

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“…Compared to artificial polishing processes, it shows higher removal efficiency, excellent removal of mid-spatial frequencies, and the ability to control the edge form [ 34 , 35 ]. Walker et al [ 36 ], Beaucamp et al [ 37 , 38 ], and Su et al [ 39 ] used bonnet tools to polish optical lenses, such as aspherical lenses, molds, freeform surfaces, and structured surfaces, achieving satisfactory surface quality. However, the removal rate of the used bonnet tools was low, so the overall process was still inefficient.…”

Section: Introductionmentioning

confidence: 99%

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

Wang

et al. 2022

Materials

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Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields.

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Simulation and experimental study on form-preserving capability of bonnet polishing for complex freeform surfaces

Cited by 26 publications

References 28 publications

The Tailored Material Removal Distribution on Polyimide Membrane Can Be Obtained by Introducing Additional Electrodes

The Tailored Material Removal Distribution on Polyimide Membrane Can Be Obtained by Introducing Additional Electrodes

Investigation on Surface Integrity of Nodular Cast Iron QT700-2 in Shape Adaptive Grinding

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

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