Ultrasonic vibration assisted machining with harder abrasives than the material to be machined can improve the quality
of machined surface and manufacturing efficiency. Therefore, we integrated ultrasonic vibration (UV) into a recently
developed technique chemo-mechanical bound-abrasive polishing in anticipation of further increasing the material
removal rate (MRR) and/or surface roughness. The preliminary results indicate that ultrasonic vibration assisted
chemo-mechanical bound-abrasive polishing can lead to increased material removal rate of manufactured optics while
leaving the surface roughness comparable to conventional chemo-mechanical bound-abrasive polishing. The great MRR
is attributed to the superiority of UV-assisted chemo-mechanical bound-abrasive polishing in discharging resultant swarf
during machining.
We incorporated ultrasonic vibration into recently developed fixed-abrasive pellets in an attempt to enhance
MRR and/or to improve manufactured surface quality. A prototype ultrasonic vibrator, the heart of the polishing head,
was designed and the related experimental work was performed on an in-house built setup in conjunction with the
constructed head. The vibrator is devised for the generation of 2-D tool path despite using only one actuator in lieu of
two actuators in conventional 2-D ultrasonic machining systems. We then combined the ultrasonic vibration with fixed
abrasive polishing pellets to machine fused silica glass. Machining experiments reveal that MRR is considerably
increased up to <50% upon the introduction of ultrasonic vibration (UV) whilst surface roughness is not degraded
appreciably.
This paper describes the development of a centerless grinding unit used for precisely processing ferrules, a key component of optical fiber connectors. In conventional processing procedure, the outer diameter of a ferrule is ground by employing a special machine tool, i.e., centerless grinder. However, in the case of processing small amount of ferrules, introducing a centerless grinder leads to high processing cost. Therefore, in order to take measures against this problem, the present authors propose a new centerless grinding technique where a compact centerless grinding unit, which is composed of an ultrasonic elliptic-vibration shoe, a workrest blade, and their respective holders, is installed on a popular surface grinder to perform the centerless grinding operations for outer diameter machining of ferrules. In this work, a unit is designed and constructed, and is installed on a surface grinder equipped with a diamond grinding wheel. Then, the performance of the unit is examined experimentally followed by grinding tests of ferrule’s outer diameter. As a result, the roundness of the ferrule’s outer diameter improved from the original value of around 3μm to the final value of around 0.5 μm, confirming the validity of the new technique.
We investigated the polishing effect of magnetic polishing liquid (MPL) made of abrasive particles and a newly developed magnetic responsive fluid, magnetic compound fluid (MCF) as intelligent or smart fluid. By applying steady and fluctuating magnetic fields, we investigated the polishing effects of the magnetic fields, varying the kinds of polishing material and the components of the MPL. In order to explain the cause of the experimental results, we investigated the apparent viscosity of the MCF and MPL, and used microscopic to investigate behavior of the particles in the MCF and MPL. We clarified the mechanisms governing the polishing effects through the use of a model based on the observation of the particles.
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