Abstract
With the development of electronics and optical industry, the high-efficiency ultra-precision polishing technologies of flat and curved surfaces are in high demand. The traditional magnetorheological polishing technology, using flexible polishing head, has the disadvantages of low polishing efficiency and small processing area. In this study, a novel tray-type magnetorheological polishing process using low-frequency alternating magnetic field excitation was developed to improve the efficiency of magnetorheological polishing for large surfaces and to make polishing magnetorheological cluster generate a cyclical fluctuation up and down, and then improve the cross-cutting effects of abrasives. With the developed excitation system, a large bowl-shaped varying magnetic field was generated in the working area, and the effects of current frequency, working gap, trough rotation speed, and workpiece rotation speed on the improvement rate of surface roughness and material removal rate were systematically investigated. A series of experiments were conducted on K9 glass specimens to verify the polishing performance. Experimental results show that the surface roughness of K9 glass was improved from 567.08 to 9.63 nm in 120 min.
Highlights
With the development of electronics and optical industry, the high-quality and high-efficiency polishing technologies of flat and curved surfaces are in high demand.[1,2] Magnetorheological finishing (MRF) is a flexible polishing technology in which material is removed by mutual friction between the workpiece surface and the hardened MR fluid in the presence of a magnetic field
MRF is regarded as a high-quality, non-damage, ultra-precision polishing process based on viscoplastic MR polishing tool.[3]
This study investigated the magnetic flux density distribution of polishing region under low-frequency alternating magnetic field (LFAMF) excitation and fabricated a set of MR polishing devices to investigate the effect of fluctuating MR cluster on polishing behavior
Summary
With the development of electronics and optical industry, the high-quality and high-efficiency polishing technologies of flat and curved surfaces are in high demand.[1,2] Magnetorheological finishing (MRF) is a flexible polishing technology in which material is removed by mutual friction between the workpiece surface and the hardened MR fluid in the presence of a magnetic field. The ‘‘spot’’ contact type utilizes a flexible polishing head to realize the polishing by constantly changing the contact point of the workpiece (Figure 1(a)). The ‘‘line’’ contact type MR polishing usually adopts a permanent magnet, and the polishing wheel is attached with axle vertical milling machine or lathes, which functions to a flexible ball-end milling
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