Study on the manufacturing process controlling for aspheric surface ballonet polishing

Ballonet polishing tools, soft gasbags filled with compressed gas, have already been one of the most reliable tools in curved surface polishing due to their adaptability to change their shape to fit the worked surfaces with the same contact stress everywhere. When the internal pressure of the gasbag is adjusted on-line, the contact stress could be controlled as you want. But, because of the tensile stress of the gasbag's material, the internal pressure could not identify the real contact condition anymore. In this paper, the contact force is used to identify the real contact condition for workpieces of aspheric surfaces which is indispensable to the polishing process control. Based on the measured internal pressure of the gasbag and the on-line-controlled contact force in the normal direction, this paper studies the arithmetic of the contact area for aspheric surfaces, finds a way to eliminate the great difference of machining speed, and advances an arithmetic of the machining time for material removal controlling in the process of aspheric surface ballonet polishing. A real ballonet polishing system is developed for aspheric surfaces, and experiments show that it is a better way by controlling the contact force rather than by controlling the internal pressure in the process of aspheric surface ballonet polishing.

[1]  Toshimichi Moriwaki,et al.  Development of Ultrasonic Vibration Assisted Polishing Machine for Micro Aspheric Die and Mold , 2006 .

[2]  Zhaowei Zhong,et al.  Optimization of the chemical mechanical polishing process for optical silicon substrates , 2012 .

[3]  Andreas Geiss,et al.  Mathematical modelling of influence functions in computer-controlled polishing: Part II , 2008 .

[4]  Yutaka Yamagata,et al.  A study on optimal compensation cutting for an aspheric surface using the Taguchi method , 2010 .

[5]  George A. Rovithakis,et al.  Force/position tracking for a robotic manipulator in compliant contact with a surface using neuro-adaptive control , 2007, Autom..

[6]  Hocheol Lee,et al.  Airbag tool polishing for aspherical glass lens molds , 2010 .

[7]  Eun-Sang Lee,et al.  A study on optimum grinding factors for aspheric convex surface micro-lens using design of experiments , 2007 .

[8]  Y. Karayiannidis,et al.  Force/position tracking for a robotic finger in compliant contact with a surface using neuro-adaptive control , 2006, 2006 IEEE Conference on Computer Aided Control System Design, 2006 IEEE International Conference on Control Applications, 2006 IEEE International Symposium on Intelligent Control.

[9]  Mahmudur Rahman,et al.  Development of an on-machine profile measurement system in ELID grinding for machining aspheric surface with software compensation , 2008 .

[10]  Shaohui Yin,et al.  Profile error compensation in ultra-precision grinding of aspheric surfaces with on-machine measurement , 2010 .

[11]  Cheng-Tang Pan,et al.  Fabrication of aspheric surface using ultraprecision cutting and BMG molding , 2009 .

[12]  Fengfeng Xi,et al.  Modeling and control of automated polishing/deburring process using a dual-purpose compliant toolhead , 2008 .

[13]  Jianming Zhan,et al.  Study on error compensation of machining force in aspheric surfaces polishing by profile-adaptive hybrid movement–force control , 2011 .

[14]  E. E. Bibik.  Mechanochemistry of metal polishing with an abrasive suspension , 2010 .

[15]  Min Cheol Lee,et al.  Intelligently automated polishing for high quality surface formation of sculptured die , 2002 .

[16]  Dongwu Yang.  Force Balance Characteristics and Pretension Design of Asymmetric Cable Net Parabolic Antenna , 2009 .

[17]  F. Xi,et al.  Modeling surface roughness in the stone polishing process , 2005 .

[18]  Sukhoon Jeong,et al.  Mechanical effects of polishing pad in copper electrochemical mechanical deposition for planarization , 2010 .

[19]  Di Zheng,et al.  NC polishing of aspheric surfaces under control of constant pressure using a magnetorheological torque servo , 2012 .

[20]  Mahmoud Farzin,et al.  Improving the quality of surface in the polishing process with the magnetic abrasive powder polishing using a high-frequency induction heating source on CNC table , 2011 .

[21]  Fritz Klocke,et al.  Material Removal Mechanisms in Lapping and Polishing , 2003 .

[22]  Jianming Zhan,et al.  An oblique ultrasonic polishing method by robot for free-form surfaces , 2000 .

[23]  Sihai Yu,et al.  A New Aspheric Surfaces Polishing by Parallel Orthogonality Movement/Force Servomechanism , 2011 .

[24]  D. S. Kim,et al.  A robust trajectory tracking control of a polishing robot system based on CAM data , 2001 .

[25]  Shivakumar Raman,et al.  Basic observations in the flat lapping of aluminum and steels using standard abrasives , 2009 .

[26]  Christian Brecher,et al.  Finishing Complex Surfaces with Zonal Polishing Tools , 2008 .

[27]  Wei Zhang.  Research on Digital Simulation and Experiment of Removal Function of Bonnet Tool Polishing , 2009 .