Abrasive Film Research Articles

Innovative Solutions in the Design of Microfinishing Attachments for Surface Finishing with Abrasive Films

The study introduces new technologies of microfinishing, which are primarily aimed at cylindrical surfaces but with machining effectiveness, precision, and surface longevity. In the newly proposed dual-zone microfinishing method, symmetrical abrasive film feeding systems are adapted with a lever mechanism and a pivoting pressing assembly to simultaneously conduct processing in two zones. With such a design, uniform force distribution is ensured, while mechanical deformation is reduced to raise the utility of the abrasive film and lower scraps for better economic performance. Also, the application of microfinishing operations combined with carbon layer deposition using graphite-impregnated abrasive films is introduced as a novel method. This process combines surface refinement and the forming of wear-resistant carbon coatings into one single operation, resulting in increased wear resistance and reduced forces of friction. Further stabilization of the conditions for microfinishing is achieved by immersing the processing zone in a fluid medium due to increased lubrication, improvement in heat dissipation, and the optimization of surface properties. It is particularly suitable for high-precision applications and a maintenance-free environment such as military, vacuum, and low-temperature systems. The experimental results show the effectiveness of the proposed methodologies, underscoring their ability to create remarkably smooth surfaces and very robust carbon textures simultaneously.

Carbon Texture Formation on the Surface of Titanium Alloy Grade 5 (Ti–6Al–4V) During Finishing with Abrasive Films

This research explored the formation and effects of carbon layers on Grade 5 titanium alloy (Ti–6Al–4V) surfaces during a microfinishing process using both traditional abrasive films and graphite-coated abrasive films. The study tried to appraise the effect of using graphite-coated films in the microfinishing process concerning surface roughness. Microfinishing with an abrasive film impregnated with diamond particles and an additional coating of graphite was performed to minimize surface roughness and enhance the overall performance of the surface. As a result, it was shown that after processing, the uniform carbon texture formed by the graphite-coated film significantly improved the lubricating and thermal properties. Energy dispersive spectroscopy (EDS) analysis confirmed the homogeneity of carbon distribution over the whole treated surface. Moreover, the graphite-coated films enabled us to obtain smoother surfaces with improved tribological properties. The study therefore concluded that the inclusion of graphite in the abrasive films is necessary for effecting surface modification in light of considerable improvements in surface quality and performance, especially where the wear needs to be reduced and the integrity of the surface maximized.

Unit Load of Abrasive Grains in the Machining Zone During Microfinishing with Abrasive Films.

This work investigates the contact between abrasive particles and workpieces in microfinishing processes with special consideration given to the determination of unit force, unit pressure, and grain, the forces exerted by individual abrasive grains. A detailed methodology was established for measuring the contact area, penetration depth, and circumferences of grain imprints at depths corresponding to multiples of the total height of the abrasive film, represented by the parameter Sz. The following depths were analyzed: 0.05 Sz, 0.15 Sz, 0.25 Sz, and 0.35 Sz. Results show that the areas closer to the central microfinishing zone bear the highest unit pressures and forces and, thus, contribute dominantly to material removal. It was further found that near the edges of the contact zone, the pressure and force have been reduced to lower material removal efficiency. The non-uniform geometry of abrasive particles was found to significantly affect contact mechanics, more at shallow depths of penetration, whereas the shape of the apex defines the nature of the interaction. A parabolic force and pressure distribution were evident for the irregular load distribution of the microfinishing area. The result brings out the need for further refinement in the design of the abrasive film and pressure distribution in order to achieve improvement in uniformity and efficiency during microfinishing. It would bring out valuable insights on how to improve the effectiveness of an abrasive film and ways of optimizing the process conditions. The results provide a founding stone for further advancement of knowledge in the grain-workpiece interaction, enabling better surface quality and more reliable microfinishing processes.

Evaluation of Surface Finishing Efficiency of Titanium Alloy Grade 5 (Ti-6Al-4V) After Superfinishing Using Abrasive Films.

Ti-6Al-4V is the most commonly used alpha-beta titanium alloy, making it the most prevalent among all titanium alloys. The processed material is widely employed in aerospace, medical, and other industries requiring moderate strength, a good strength-to-weight ratio, and favorable corrosion resistance. A microfinishing process on the titanium alloy surface was conducted using abrasive films with grain sizes of 30, 12, and 9 μm. Superfinishing with abrasive films is a sequential process, where finishing operations are performed with tools of progressively smaller grains. The surface topography measurements of the workpiece were taken after each operation. The experiment was in the direction of developing a new surface smoothness coefficient considering the number and distribution of contact points so as to properly evaluate the quality of the surface finishing. The results showed that the finest-grain films gave the most uniform contact points, thus offering the best tribological characteristics; the 9 LF (micron lapping film) tools gave the smoothest surfaces (Sz = 2 µm), while the biggest-grain films, such as the 30 FF (micron microfinishing film), were less effective since large protrusions formed. This is a suitable study to explore the optimization paths for the superfinishing of titanium alloys, with implications for improving the performance and longevity of components in critical industrial applications.

Ultrathin Carbon Textures Produced on Machined Surfaces in an Integrated Finishing Process Using Microabrasive Films.

This study presents research into the unique method of depositing carbon layers onto processed surfaces, during finishing with abrasive films, on a global basis. The authors of this article are holders of the patent for this method. What makes this technology outstanding is that it integrates processes, whereby micro-finishing and the deposition of a carbon layer onto freshly exposed surface fragments is achieved simultaneously, in a single process. Among the main advantages accruable from this process is the reduction of surface irregularities, while the deposition of a carbon layer is achieved simultaneously. Ultrathin graphite layers can be widely used in conditions where other methods of reducing the coefficient of friction are not possible, such as in regard to micromechanisms. This article illustrates the application of carbon coating, end on, on a surface processed with abrasive film, containing intergranular spaces, saturated with graphite. Thin carbon layers were obtained on two substrates that did not contain carbon in their initial composition: soda-lime glass and a tin-bronze alloy. It was performed through microscopic examinations of the produced surface, roughness analyses of these surfaces, and analysis of the chemical compositions determined by two methods, namely EDS and GDOES, proving the existence of the coatings. The aim of this paper is to prove the possibility and efficiency of using graphite-impregnated lapping films in the deposition process of carbon films, with improved surface smoothness, durability, and wear resistance. The produced coatings will be tested in regard to their operational properties in further research. The authors underline the potential of this method to revolutionize surface treatment processes, due to the significant advantages it offers across various industries.

Evaluation of the Surface Topography of Microfinishing Abrasive Films in Relation to Their Machining Capability of Nimonic 80A Superalloy.

This study investigates the surface topography of microfinishing abrasive films and their machining capability on the Nimonic 80A superalloy, a high-performance nickel-based alloy commonly used in aerospace and gas turbine engine applications. Surface analysis was conducted on three abrasive films with nominal grain sizes of 30, 15, and 9 μm, exploring wear patterns, contact frequency, and distribution. To assess the distribution of grain apexes, Voronoi cells were employed. Results revealed distinct wear mechanisms, including torn abrasive grains and cracked bond surfaces, highlighting the importance of efficient chip removal mechanisms in microfinishing processes. Larger grain sizes exhibited fewer contacts with the workpiece but provided more storage space for machining products, while smaller grain sizes facilitated smoother surface finishes. The research demonstrated the effectiveness of microfinishing abrasive films in reducing surface irregularities. Additionally, surface analysis of worn abrasive tools provided insights into wear mechanisms and chip formation, with the segmentation of microchips contributing to efficient chip removal. These findings underscore the significance of selecting appropriate abrasive films and implementing effective chip removal mechanisms to optimize microfinishing processes and improve surface finishing quality in advanced material machining applications. It is worth emphasizing that no prior research has investigated the microfinishing of components crafted from Nimonic 80A utilizing abrasive films, rendering this study truly unique in its contribution to the field.

Effects of Pressure Rollers with Variable Compliance in the Microfinishing Process Utilizing Abrasive Films.

This article presents a comprehensive investigation into pressure rollers utilized in the microfinishing process, covering aspects such as design, experimental properties, compliance, and finite element simulation. Prototype pressure rollers with unconventional elastomer configurations were designed and analyzed to explore their effectiveness in achieving superior surface finishes. Experimental analysis and finite element simulations were conducted to gain insights into the performance and behavior of these pressure rollers under various loading conditions. This study addresses the validation of constitutive material models used in finite element simulations to ensure accuracy and reliability. The results indicate that the applied material model, validated through experimental analysis, accurately predicts pressure roller behavior. Finite element simulations reveal distinct contact zone patterns and stress distributions across the contact surfaces, highlighting the importance of considering deflection-induced variations in contact behavior. Additionally, the investigation evaluates the effectiveness of different pressure rollers in removing surface irregularities during the microfinishing process. Roller R3 demonstrates the highest efficacy in removing surface peaks, suggesting its potential for achieving superior surface finishes. Overall, this research contributes to the advancement of microfinishing techniques by providing insights into pressure roller design, performance, and behavior, thereby optimizing microfinishing processes to produce high-quality components. The urgency of this study arises from the growing need for exceptional surface finishes in various industrial sectors. With manufacturing industries increasingly pursuing high-precision components boasting flawless surface quality, the significance of microfinishing processes is highlighted.

Superfinishing with Abrasive Films Featuring Discontinuous Surfaces.

This study introduces innovative designs for abrasive tools aimed at enhancing surface finishing processes. Prototypes consisting of non-continuous abrasive films with discontinuous surface carriers and abrasive layers were developed to improve the efficiency and effectiveness of the smoothing process. Four distinct abrasive films with varying nominal grain sizes were fabricated to explore the versatility and efficacy of the prototypes. The results indicate that the incorporation of carrier irregularities significantly influences surface finishing processes, leading to improvements in material removal efficiency and surface quality. Longitudinal discontinuities facilitate faster removal of irregularities from workpiece materials, reducing the risk of deep scratches on surfaces. Additionally, this study highlights the importance of tool motion patterns in optimizing material removal processes and ensuring surface quality. The integration of carrier irregularities with additional oscillatory tool motion shows promise for further improving surface quality. These findings advance our understanding of abrasive machining processes and provide valuable insights for optimizing abrasive tool designs and machining strategies for enhanced surface finishing.

Morphology of Microchips in the Surface Finishing Process Utilizing Abrasive Films.

In this study, the surface of new lapping films was analyzed, and the lapping finishing process was applied to RG7 tin bronze alloy. The research focused on examining lapping films with electrocorundum grains of nominal sizes 30, 12, and 9 μm, commonly used for achieving smooth surfaces. The manufacturing process involves placing abrasive grains and binder onto a polyester tape, resulting in a heterogeneous distribution of abrasive grains. The study investigates the impact of this random distribution on the performance of lapping films during material removal. Scanning electron microscopy was used to analyze the surface structure of abrasive films, revealing distinctive structures formed by the specific aggregation of abrasive grains. This study explores the influence of different nominal grain sizes on surface finish and aims to optimize lapping processes for diverse applications. The research also delves into microchip analysis, examining the products of the lapping film finishing process. Microchips were observed directly on the abrasive tool surface, revealing insights into their morphology and distribution. The chip segmentation frequency was determined, and they amounted to approximately 0.8 to 3 MHz; these are very high frequencies, which are unique for known chip-forming processes.

SERS active substrates for neonicotinoids studies

Different basic substrates, – Si wafers, (001) SiO2, printer paper, Al2O3, micro-processed (001) SiO2 or diamond abrasive films, have been used to create active Ag and Au nanostructures. In this lecture, we report the use of pulsed-laser deposition and thermal deposition both followed by pulsed-laser annealing; the results are compared. Advanced substrates of Au and Ag on Si were produced in view of surface-enhanced Raman spectroscopy (SERS) detection of the imidacloprid (Nuprid 200 SP) neonicotinoid insecticide in amounts much smaller than those ordinarily applied in agricultural medicine. The SERS peaks intensity rose by at least one order of magnitude after the pulsed-laser annealing of the metal films and nanoparticles arrays formation. The enhancement factor (EF) was estimated to be >5×104, the limit of detection (LOD) reached being < 0.5 nM. The properties of the advanced substrates were compared and discussed. The importance of SERS as a relatively inexpensive and simple method is emphasized in regulating, monitoring and controlling the level of such chemicals as environmental pollutants, thus precluding harming the human and, especially, honey bees’ health.

Synergistic effect of aminosilane and K2CO3 on improving Chemical Mechanical Polishing performance of SiO2 dielectric layer

Chemical Mechanical Polishing (CMP) is a widely used surface treatment process in integrated circuit manufacturing for global planarization of the surface layers of various materials. The CMP slurry is regarded as one of the key determinants of planarization performance, considering the synergistic effect of its abrasive and other chemical components. As the component size is decreased to the molecular or even atomic scale, ways to achieve a high material removal rate of the SiO2 dielectric layer while maintaining high surface topography quality have become a challenge for the integrated circuit manufacturing industry. In this work, the synergistic effect of aminosilane and K2CO3 in the SiO2 CMP process was identified. A material removal rate of 248 nm/min and surface roughness of 0.374 nm was achieved under a pH of 11, SiO2 abrasive of 12 wt%, K2CO3 concentration of 0.12 M, and 3-aminopropyltriethoxysilane (APTES) concentration of 60 ppm. Through X-ray photoelectron spectroscopy (XPS), it was found that APTES can be adsorbed on the surface of SiO2 film through chemical bonding. Further, it was proved by fourier infrared spectroscopy (FTIR) that APTES could be combined with abrasive particles and coated on the surface of abrasive to realize the modification. The changes in particle size and zeta potential of the slurry were measured with a laser particle size analyzer. The studies suggested that under the influence of K2CO3, the hydration reaction on the SiO2 surface was intensified, the chemical bonding between APTES and the silanol (Si–OH) dangling bond on both surface of abrasive and SiO2 film was established, which enhanced the chemical reaction on the wafer surface. Finally, a material removal model of SiO2, characterized by the synergistic effect of APTES and K2CO3 was proposed based on the study.

The tribological performance of W-DLC in solid–liquid lubrication system addivated with Cu nanoparticles

Judicious selection of additives having chemical and physical compatibility with the DLC films may help improving the triboligical properties and durability life of DLC-oil composite lubrication systems. In this study, Cu nanoparticles were added to PAO6 base oil to compose a solid-liquid composite lubrication system with W-DLC film. The effects of nanoparticle concentration, test temperature and applied load on tribological performance were systematically studied by a ball-on-disk friction test system. The tribological results illustrated that Cu nanoparticles could lower the coefficient of friction (COF) and dramatically reduce the wear rates of W-DLC films. The optimal tribological behavior was achieved for the 0.1 wt% concentration under 30 °C and the applied load of 100 N. The test temperature and applied load were vital influencing factors of the solid–liquid lubrication system. The bearing effect and soft colloidal abrasive film of spherical Cu nanoparticle contributed to the excellent tribological performance of the composite lubrication system under mild test conditions, meanwhile, the local delamination of W-DLC film and oxidation were the main causes of the friction failure under harsh test conditions. With test temperature and applied loads increase the degree of graphitization of the W-DLC film increased. In conclusion, there are several pivotal factors affecting the tribological performance of solid–liquid lubrication systems, including the number of nanoparticles between rubbing contact area, graphitization of the worn W-DLC films, tribofilms on the worn ball specimens and oxidation formed in friction test, and the dominant factor is determined by the testing condition.

Advanced silver and gold substrates for surface-enhanced Raman spectroscopy of pesticides

Silver and gold nanostructures were fabricated by thermal deposition followed by laser annealing on novel type substrates - diamond abrasive films and scratched quartz plates. The morphology and optical properties of the nanostructures were studied and they were applied for surface-enhanced Raman spectroscopy of the insecticide Karate Zeon 5 CS (lambda-cyhalothrin). The limit of detection of about ≈50 µM was estimated. Advanced substrates for surface-enhanced Raman spectroscopy of pesticides were developed. For this purpose alumina, quartz, paper, and diamond abrasive films substrates were used on which silver and gold nanostructures were produced using pulsed laser, ion-beam or thermal deposition, and laser annealing. The effectiveness of these active substrates for detecting several pesticides was evaluated and discussed.

Study on Soluble Fixed Soft Abrasive Polishing Film Used on Optical Fiber Connector

The end face of an optical fiber connector can be easily contaminated, the curvature radius of the end face can be difficult to guarantee, and the polishing film might not be durable during polishing. To solve these problems, a soluble fixed soft abrasive film polishing method was proposed. Through dyeing and dissolving, tensile strength, and polishing experiments, the influence of the binder and abrasive on polishing film production was studied. The results showed that when the content of each component was 15 wt% epoxy resin, 5 wt% polyacrylic resin, 75 wt% bimodal SiO2, and 5 wt% other additives, the polishing film had superior workpiece polishing quality and durability. After polishing, the end surface of the fiber connector was smooth and clean, the surface morphology of the curved surface was complete, and the surface roughness reached Ra 5 nm.

Określanie zdolności diamentowych folii ściernych do mikrowygładzania

In order to determine the micro-finishing abilities of diamond abrasive films, surface topography was analyzed using confocal microscopy OLS 4000 Olympus. In the analysis of stereometric features of the abrasive surface, it was considered that during the micro-finishing process the abrasive surface is pressed against the workpiece. The procedure for determining the changes in topography of the film surface in the treatment area was developed as a result of elastic deformations of the film carrier, the grain binding binder and the pressure roller. New parameters for the activity of abrasive grains were developed and the values of grain hollows, depending on the pressure value in the machining zone and the nominal size of the grain (3, 9, 15, 30 μm) were determined.

Multiple-beam fibre reflection interferometer based on an all-dielectric diffraction structure

We report experiments aimed at making a fibre reflection interferometer based on all-dielectric diffraction structures for the range 1500 – 1600 nm. The diffractive scattering structure of the input mirror of the interferometer is produced on the fibre end face by damaging it using abrasive diamond film with a grain size of a few microns. As a result, sharp reflection peaks are obtained for two interferometers, with the following parameters: finesse, 100 and 11; contrast, 2 and 60, respectively. Such an interferometer can, in principle, combine high contrast and high finesse.

Analiza form zużycia i trwałości folii ściernych

The paper analyzes the wear and durability of abrasive films designed for microsmoothing produced by electrostatic method. In order to carry out tool wear studies, a microgrinding process was performed using an abrasive film with a nominal grain size of 15 μm. The next step was the study, using scanning microscope. Crushed grains were observed on the surface of the foil, overflows, and extremely high temperatures in the treatment zone, above 1400°C, which resulted in the formation of spherical chips.

Analiza aktywności ziaren ściernych w procesie wygładzania foliami ściernymi

In the paper the active of abrasive grains in the films abrasive finishing process was analyzed. The results of the simulation of surface smoothing process were presented. The subject matter of the analysis was a 3IDLF diamond abrasive film.

Effect of pre-treatment polishing on fabrication of anodic aluminum oxide using commercial aluminum alloy

Aluminum anodizing is a process in which metal is oxidized with an electrochemical method to make a metallic oxide. Because it can be used to manufacture an Anodic aluminum oxide (AAO) with dozens to hundreds of nanoscale pores that are vertically and uniformly arranged, it is widely applied in a variety of fields. In particular, most of the pre-treatment methods in the anodic oxidation processes using a high-purity aluminum adopt surface treatment through electrolyte polishing. In this study, complex polishing was performed using an abrasive film and Magnetorheological (MR) fluid for a commercial aluminum alloy to produce a uniform porous oxidized aluminum. The surface roughness and surface integrity were analyzed after each process to investigate the production behavior of AAO in relation to the pre-treatment of the surface. In addition, a study was conducted on the nano-pore production by the anodizing process in accordance with the pre-treatment polishing, in terms of the work-hardening and residual stress. Thus, in the anodic oxidation process, it was possible to generate uniform nano-pores when surface integrity including surface roughness and residual stress distribution of the aluminum alloys are excellent. Test results showed that the polishing process using the MR fluid did not generate process scratches and pits, but could effectively remove the work-hardening and compressive residual stress, proving that MR fluid polishing method is a suitable pre-treatment process to produce nano-pores in the anodizing process.

Communication—Reduction of Friction Force between Ceria and SiO2 for Low Dishing in STI CMP

We investigated the effect of friction force between ceria abrasive and SiO2 film on dishing in STI CMP. The control of adsorption amount of poly acrylic acid (PAA) on ceria surface led to the reduction of the friction force during CMP. The reduced friction force by a thick surface layer on ceria resulted in the decrease of the dishing in STI structure during over-polishing process. In the patterned wafer, the dishing decreased from 976 to 594 Å/min at 37.5% pattern density (Si3N4/SiO2 = 30/50 μm) as a maximum adsorption amount increased from 0.49 to 0.64 mg/m2.