A Novel Polishing Process with Rigid-Flexible Composite Structure Plate and Its Performance in Polishing Sapphire Wafer

A novel flexible polishing process has been developed for sapphire wafer by using a polishing plate with rigid-flexible composite structure to satisfy the demands of excellent surface shape accuracy and high surface topography quality simultaneously. This new polishing plate was fabricated by alternately casting and curing the ring structure of soft and hard unsaturated resins. It is found that the overall stiffness of the polishing plate is improved due to the “hard support frame” of rigid-flexible polishing plate, as well as the ability of removal selectivity of the polishing plate is strengthened. The topography quality and shape accuracy of sapphire wafer polished by presented novel polishing process have been compared with those polished by conventional flexible polishing, respectively. Both experiment and simulation results are shown that the surface roughness and topographical variations of sapphire wafer polished by the novel rigid-flexible composite structure polishing plate have been greatly improved. Comparing with the conventional flexible polishing, the surface shape accuracy of the sapphire wafer polished by the presented novel polishing process can be improved by 54.1%.

Material removal predictions in the robot glass polishing process using machine learning

Robot polishing is increasingly being used in the production of high-end glass workpieces such as astronomy mirrors, lithography lenses, laser gyroscopes or high-precision coordinate measuring machines. The quality of optical components such as lenses or mirrors can be described by shape errors and surface roughness. Whilst the trend towards sub nanometre level surfaces finishes and features progresses, matching both form and finish coherently in complex parts remains a major challenge. With increasing optic sizes, the stability of the polishing process becomes more and more important. If not empirically known, the optical surface must be measured after each polishing step. One approach is to mount sensors on the polishing head in order to measure process-relevant quantities. On the basis of these data, machine learning algorithms can be applied for surface value prediction. Due to the modification of the polishing head by the installation of sensors and the resulting process influences, the first machine learning model could only make removal predictions with insufficient accuracy. The aim of this work is to show a polishing head optimised for the sensors, which is coupled with a machine learning model in order to predict the material removal and failure of the polishing head during robot polishing. The artificial neural network is developed in the Python programming language using the Keras deep learning library. It starts with a simple network architecture and common training parameters. The model will then be optimised step-by-step using different methods and optimised in different steps. The data collected by a design of experiments with the sensor-integrated glass polishing head are used to train the machine learning model and to validate the results. The neural network achieves a prediction accuracy of the material removal of 99.22%. Article highlights First machine learning model application for robot polishing of optical glass ceramics The polishing process is influenced by a large number of different process parameters. Machine learning can be used to adjust any process parameter and predict the change in material removal with a certain probability. For a trained model,empirical experiments are no longer necessary Equipping a polishing head with sensors, which provides the possibility for 100% control

Effect of Diamond Polishing and Thermal Treatment on Carbon Paramagnetic Centers’ Nature and Structure

Diamonds contain carbon paramagnetic centers (stable carbon radicals) in small concentrations (at the level of ~1 × 1012 spins/mg) that can help in elucidating the structure of the nitrogen atoms’ contaminants in the diamond crystal. All diamonds that undergo polishing are exposed to high temperatures, owing to the friction force during the polishing process, which may affect the carbon-centered radicals’ concentration and structure. The temperature is increased appreciably; consequently, the black body radiation in the visible range turns orange. During polishing, diamonds emit an orange light (at a wavelength of about 600 nm) that is typical of a black body temperature of 900 °C or higher. Other processes in which color-enhanced diamonds are exposed to high temperatures are thermal treatments or the high-pressure, high-temperature (HPHT) process in which the brown color (resulting from plastic deformation) is bleached. The aim of the study was to examine how thermal treatment and polishing influence the paramagnetic centers in the diamond. For this purpose, four rough diamonds were studied: two underwent a polishing process, and the other two were thermally treated at 650 °C and 1000 °C. The diamonds were analyzed pre- and post-treatment by EPR (Electron Paramagnetic resonance), FTIR (Fourier transform infrared, fluorescence, and their visual appearance. The results indicate that the polishing process results in much more than just thermal heating the paramagnetic centers.

Finishing of Micro-Aspheric Tungsten Carbide Mold Using Small Viscoelastic Tool

Tungsten carbide is widely used as the material of replication mold to produce small aspheric optics, and the polishing process determines the precision of the mold. However, for micro-aspheric tungsten carbide mold, the existing polishing methods are difficult to realize the from error modification during the polishing because the polishing tool is always larger than small mold. Therefore, a polishing tool which using polyester fiber cloth to wrap small-size rigid ball is used in this paper. In order to predict the tool influence function (TIF) of this polishing tool, a series of theoretical analysis and experimental verification are carried out in this paper. Firstly, by analyzing the structural and viscoelastic characteristics of the fiber cloth, the pressure distribution in the polishing contact area is determined. And the polishing speed distribution is obtained by analyzing the kinematic movement of the polishing tool; Then, combined with Preston equation, the tool influence function is derived; Afterward, through a series of single point polishing experiments, it is verified that the volume error between the theoretical removal model and the experimental removal is less than 10.8%; Finally, the tool influence function is applied to the form error corrective polishing of small size symmetric aspheric tungsten carbide mold. After one form error corrective polishing, the PV value (Peak to Valley) of form error is decreased from 0.405um to 0.068um, which verifies the effectiveness of the polishing method of small size tungsten carbide mold in form error correction.

Constrained Abrasive Jet Polishing with a Tangentially Aligned Nozzle Shroud

In order to improve surface polishing quality and efficiency for hard and brittle components, a novel nozzle with specifically designed shroud was proposed for an abrasive jet polishing process. The removal mechanism of the abrasive jet under such a nozzle was investigated by simulating the jet flow in the interaction area of the nozzle shroud and workpiece. The simulation results show that the speed of the abrasive jet increases greatly by the shroud and the direction of the jet is aligned near parallel to the workpiece surface to minimize impact damage to workpiece surface. The constrained abrasive jet polishing (CAJP) experiments were conducted on the quartz glass component, a typical hard and brittle material, showing that the material removal mainly relied on the shearing and scratching of the workpiece surface rather than the mechanical shock impacts, which is consistent with the simulation findings.

Gloss and Modelling Studies of Stone Polishing, Using Linear Polishing Machines With Rotating Heads

The ornamental stone industry has always played an important role in the world economy, particularly in building construction. Polishing the slabs to increase its gloss, is an important processing operation to enhance the beauty and richness of these natural materials. Many industrial polishing machines rely on rotating heads movement along zigzag trajectories, eroding the surface as stochastically as possible, to avoid scratches and other visual defects caused by paths too symmetric. The displacement of the polishing head after a single zigzag movement and after a single rotation have been used to quantify the polishing process as these two parameters are related with the final stone gloss and are a measure of the efficiency of the polishing process. Applying experimental and new computer simulation techniques, we studied the influence of these two tool displacement parameters on the final stone gloss, and acquired insight into the accuracy of the simulation techniques that were applied here for the first time. We concluded that: 1) a clear correlation can be established between experimental and simulation data; 2) the two displacement parameters represent an effective way to control the quality and efficiency of the polishing process; 3) there is a limit for the gloss acquired through polishing processes, so polishing above a given threshold decreases the efficiency without increasing the quality.