Abstract
An innovative approach, active flexible tool‐assisted shear thickening polishing (AFT‐STP), is introduced to overcome the limitations of low efficiency involved in the STP process of the concave surface. The principle and characteristics of AFT‐STP are presented, accompanied by the design of a flexible tool structure and the creation of an experimental setup. Utilizing the Taguchi method, experiments are planned and results are assessed via the signal‐to‐noise ratio to optimize process parameters. A variance analysis is then used to ascertain the relative influence of four key parameters—polishing speed, polishing gap, abrasive particle size, and abrasive concentration on the polishing performance of quartz glass in STP. Under the optimal parameters, a concave quartz glass workpiece with diameter Ø 20 mm and curvature radius 488 mm is polished, the average surface roughness Sa of the five measuring points on the surface decreases from 142.18 ± 8.63 (Avg. ± Std.) nm to 5.34 ± 1.16 nm in 45 min with MRR 57.3 nm min−1, and the surface defects of the processing area are completely removed, leaving only minor pits. The results show that the AFT‐STP is an effective method for high‐quality polishing of concave surfaces.
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