Article
Optics
Runmu Cheng, Longxiang Li, Donglin Xue, Xingchang Li, Yang Bai, Xiao Luo, Xuejun Zhang
Summary: A three-dimensional tool influence function (TIF) model is developed to accurately predict the influence of different polishing gaps in this study. A high-precision robot-MRF polishing strategy is proposed and validated experimentally. This research is of great significance for promoting the application of industrial robots in optical manufacturing.
Article
Engineering, Manufacturing
Minwoo Jeon, Seok-Kyeong Jeong, Jong-Gyun Kang, Woo-Jong Yeo, Young-Jae Kim, Hwan-Jin Choi, Wonkyun Lee
Summary: Magnetorheological finishing (MRF) is a deterministic process widely used in the optical manufacturing industry for its ability to remove subsurface damage and correct figures to a high level. However, like other computer-controlled polishing methods, MRF experiences the edge effect, which can affect the performance of optical components. This study analyzes the edge tool influence function (TIF) and proposes a mathematical model to predict the edge effect after MRF. Experimental results confirm the feasibility of the proposed model.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING
(2022)
Article
Optics
Quanlin Shu, Kuo Hai, Wen Huang, Lili Jiang, Shenghao Yuan, Kailong Li, Pengfei Sun, Dong Tian, Yunfei Zhang
Summary: This study focuses on the surface defects of optical components in ultraprecision optical systems such as high-energy laser systems and investigates the common comet-shaped defects in magnetorheological finishing. Through computational fluid dynamics simulation and polishing experiments, the velocity and pressure distribution during the formation of the defects are analyzed, and an optimization method for efficient removal of comet-shaped defects is proposed.
Article
Automation & Control Systems
Xiangyu Guan, Donghai Zhao, Yaxin Yu, Dunwen Zuo, Shuquan Song
Summary: In this paper, a non-uniform edge preparation method based on magnetorheological finishing is proposed. The flexible abrasive tool formed by the magnetorheological effect can achieve controllable removal and low-damage cutting edge. The edge preparation device is designed and built, and the structure of the grinding basin is optimized. Through simulation and experiment, the material removal rate and Preston coefficient of the cutting edge are analyzed, showing that magnetorheological preparation can achieve non-uniform directional quantitative removal of edge materials.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
B. O. Wang, F. E. N. G. Shi, W. A. N. L. Zhang, G. U. I. P. E. N. G. Tie, C. Song, S. H. U. A. N. G. P. E. N. G. Guo
Summary: The study demonstrates that controlling the rotation angle of the removal function and the fluctuation of the magnetorheological ribbon can effectively eliminate the mid-spatial frequency (MSF) ripple error on the surface of optical components in high-energy laser systems, thus improving the surface quality of the components.
OPTICAL MATERIALS EXPRESS
(2022)
Article
Optics
Zhifan Lin, Hao Hu, Yifan Dai, Zhong Yaoyu, Shuai Xue
Summary: This paper developed a theoretical model to describe the material removal rate and surface quality after Magnetorheological finishing (MRF) in order to better understand the material removal mechanism. Experimental results were highly consistent with the theoretical model calculated results, making the theoretical model a reference for high-efficiency and ultra-smooth MRF process.
Article
Automation & Control Systems
Prabhat Kumar Baghel, Vinod Mishra, Raj Kumar, Gufran Sayeed Khan
Summary: This paper presents an experimental investigation on ultrasonic vibration-assisted magnetorheological finishing (VAMRF) process for improved material removal rate (MRR) and surface finishing on glass optics polishing. The results show that hybrid VAMRF provides approximately 20% higher MRR and better surface micro-roughness improvement compared to conventional Ball End MRF (BEMRF). The developed hybrid process is applied in corrective polishing of glass optics and reduces the figure error (RMS) of the surface significantly.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Shiwei Liu, Hongxiang Wang, Jing Hou, Qinghua Zhang, Bo Zhong, Xianhua Chen, Mingzhuang Zhang
Summary: Magnetorheological finishing (MRF) has become the mainstream method for ultra-precision manufacturing of optics due to its high certainty and low damage. However, there are still gaps in the research on the characteristics of the tool influence function for the MRF method, which results in a lack of effective theoretical support for parameter optimization and quality improvement. This paper demonstrates the mapping relationship between various process parameters and the evaluation indexes of the influence function based on orthogonal tests. A characteristic length coefficient is proposed to suppress ripple errors. The experiment results show that selecting reasonable characteristic length coefficient and line spacing can significantly improve the final quality of the components.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Songlin Wan, Chaoyang Wei, Chen Hu, Guohai Situ, Yuchuan Shao, Jianda Shao
Summary: The proposed novel form of magnetorheological finishing tool can stabilize the surface without significant path ripple, potentially extend to other polishing tools, significantly improve optical system performance and manufacturing efficiency.
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE
(2021)
Article
Engineering, Manufacturing
Nitesh Kumar Dubey, Ajay Sidpara, Rajaram Lakkaraju
Summary: Magnetorheological fluid-based finishing is a recognized technique for precise finishing of components, with material removal depending on MR fluid ribbon's velocity and compression during interaction with the workpiece. This article investigates the ejection of magnetic and abrasive particles during carrier wheel rotation by balancing centrifugal and magnetic forces. Experimental results demonstrate reduction in MR fluid ribbon thickness and surface roughness initially decreases and then increases with increasing carrier wheel speed. The theoretical and actual departure speed of magnetic particles from the MR fluid ribbon show good agreement.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Engineering, Manufacturing
Ankit Aggarwal, Anant Kumar Singh
Summary: Ball transfer units (BTUs) are important for feed devices and conveyor systems. Fine-finishing of the ball cup surface using an electromagnetic-based magnetorheological hemispherical finishing (MRHF) tool improves the functional performance of BTUs. This study successfully designed and fabricated the MRHF tool, achieving a reduction in surface roughness and improvement in dimensional accuracy and surface characteristics.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Engineering, Mechanical
Changsheng Li, Lin Sun, Zhaoxiang Chen, Jianfang Chen, Qijing Lin, Jianjun Ding, Zhuangde Jiang
Summary: This study investigates the arc envelope grinding process of large-aperture aspherical optics and proposes a method to determine wheel setting errors. By aligning the wheels accurately and using an error compensation method, a form error of 3.4 μm is achieved for an elliptical surface.
CHINESE JOURNAL OF MECHANICAL ENGINEERING
(2022)
Article
Engineering, Mechanical
Ravi Datt Yadav, Anant Kumar Singh, Kunal Arora
Summary: The study focuses on the utilization of a new magnetorheological gear profile finishing process for fine finishing of spur gear teeth profile surfaces. A theoretical mathematical model is developed to predict the change in surface roughness during the MRGPF process, with analysis of the impact of magnetic flux density on the gear tooth profile. Experimental validation and finite element analysis were used to confirm the theoretically calculated results.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2021)
Article
Materials Science, Multidisciplinary
Nitesh Kumar Dubey, Ajay Sidpara, Rajaram Lakkaraju
Summary: A dynamic viscosity model is proposed based on the varying magnetic flux density of the neodymium permanent magnet. The model provides a better analysis of the influence function compared to standard non-Newtonian fluid models. Numerical and experimental investigations are conducted to examine the flow behavior of the MR fluid on a freeform surface and understand its influence function.
JOURNAL OF MAGNETISM AND MAGNETIC MATERIALS
(2023)
Article
Instruments & Instrumentation
Nitesh Kumar Dubey, Ajay Sidpara
Summary: The study investigates the influence function of magnetorheological finishing process through numerical simulation and experiments, analyzing the relationship between dynamic pressure, wall shear stress, and the workpiece surface. The correlation between depth of indentation and influence function is examined, with the understanding that spindle speed and working gap size affect both parameters.
SMART MATERIALS AND STRUCTURES
(2021)
Article
Optics
Jing Hou, Pengli Lei, Shiwei Liu, Xianhua Chen, Jian Wang, Wenhui Deng, Bo Zhong
JOURNAL OF THE EUROPEAN OPTICAL SOCIETY-RAPID PUBLICATIONS
(2020)
Article
Materials Science, Ceramics
Chu Wang, Hongxiang Wang, Rui Gao, Mingzhuang Zhang, Shiwei Liu, Jing Hou, Xianhua Chen
Summary: Subsurface damage (SSD) refers to fractures and deformations near the surface of brittle optical materials caused by surface lapping or grinding. Thermal healing experiments on subsurface cracks of borosilicate glass (BK7) show that factors such as temperature, crack depth, and water vapor pressure influence the healing process. The results of heat treatment on subsurface damage from grinding demonstrate the effectiveness of thermal healing in reducing damage density and depth.
CERAMICS INTERNATIONAL
(2021)
