Abstract
A novel magnetic field-assisted polishing technique was proposed for finishing 3D structured surface using a magnetic compound (MC) slurry. The MC slurry was prepared by blending carbonyl-iron-particles, abrasive grains and α-cellulose into a magnetic fluid which contains nano-scale magnetite particles. An experimental setup was constructed firstly by installing an oscillation worktable and a unit onto a polishing machine. Then, experimental investigations were conducted on oxygen-free copper workpiece with parallel distributed linear V-grooves to clarify the influence of the polishing time and abrasive impact angle on the grooves surface qualities. It was found that (1) the groove form accuracy, i.e. the form retention rate η varied with the polishing locations. Although the form retention rate η deteriorated during the polishing process, the final η was greater than 99.4%; (2) the effective impact angle θm affected the material removal and form accuracy seriously. An increase of the absolute value θm resulted with an increase of material removal rate and a decrease of the form accuracy; (3) the work-surface roughness decreased more than 6 times compared with the original surface after MC slurry polishing. These results confirmed the performance of the proposed new magnetic field-assisted polishing method in the finishing of 3D-structured surface.
Highlights
To bring down the cost of 3D structured optical system, hot pressing and injection molding are more and more widely used to form the polymer or glass elements
The form retention rate η deteriorated during the polishing process, the final η was greater than 99.4%; (2) the effective impact angle θm affected the material removal and form accuracy seriously
An increase of the absolute value θm resulted with an increase of material removal rate and a decrease of the form accuracy; (3) the work-surface roughness decreased more than 6 times compared with the original surface after magnetic compound (MC) slurry polishing
Summary
To bring down the cost of 3D structured optical system, hot pressing and injection molding are more and more widely used to form the polymer or glass elements. The existing traditional and untraditional methods, such as diamond cutting and grinding, could achieve great accuracy on die materials.[1] for the final molding requirement, subsequent polishing of the machined surface is normally necessary to remove the feed marks caused by the pre-machining, and further improve the surface roughness.[2] Since the traditional polishing operations are limited to processing the flat surface, abrasive fluid polishing (AFM) is widely considered to be an efficient technique for 3D structures. In the AFM, the abrasive fluid, i.e., magnetorheological fluid (MRF) slurry or magnetic fluid (MF) slurry can flow through the structure surface, effectively performing erosion.[3,4,5] As for the MRF and MF, the magnetic pressure and apparent viscosity of MF slurry are smaller than those of MRF under the same magnetic field; the particles are more stably distributed in the MF slurry.[6]. The object of this paper is to develop a novel method for the effective finishing of V-grooves using MC slurry
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