3D surface topography assessment of the effect of different electrolytes during electrochemical polishing of EDM surfaces

In many countries the most common polishing practice in die making is to hand polish the part as a finishing operation after the electro discharge machining process (EDM). The usual polishing abrasives are silicon carbide paper and diamond paste of different grit sizes.However, during the last decade researchers especially in Japan and the USA have tried to combine EDM and electrochemical machining (ECM) in one machine so as to use the positive aspects of each individual process. The ECM process uses high density, typically 50 A/cm², and also a pulse current with a servo-controlled electrode. These investigators have mostly used sodium nitrate solutions (of different concentrations) as the electrolyte.This paper deals with an experiment that was undertaken in order to assess the effect of four different electrolytes in an electrochemical polishing process (ECP) on the surface topography of EDM surfaces. The primary set of 3D surface parameters was used as a basis to characterise the surface produced by the combined processes in different electrolytic media.     

Empirical approach to develop a multilayer icebonded abrasive polishing tool for ultrafine finishing of Ti-6Al-4V alloy

This paper covers the development of a multilayer icebonded abrasive polishing (IBAP) tool for multistage polishing of Ti-6Al-4V alloy specimens based on a systematic study that determined the number of layers, thickness of each layer, and the type, size and concentration of abrasives in each layer. Based on this study, a three-layered IBAP tool with the bottom layer consisting of soft aluminum oxide abrasives of 3?µm size with 5% concentration, the middle layer with moderately hard silicon carbide abrasives of 8?µm size with 10% concentration and the top layer with hard boron carbide abrasives of 15?µm size with 30% concentration was formulated for ultrafine finishing of Ti-6Al-4V alloy specimen in a single setup. The performance of the three-layered IBAP tool assessed in terms of finish and morphology over the work surface showed 81% improvement in surface finish, showing its effectiveness over a single-layered IBAP tool. Polishing studies have clearly demonstrated the generation of ultrafine surfaces, yielding a finish of 37?nm while the morphological studies on the polished surface have shown a nearly scratch-free surface on the Ti-6Al-4V alloy.     

A study on the effect of polishing fluid volume in ball end magnetorheological finishing process

Ball end magnetorheological finishing is a unique process that utilizes a magnetically controlled ball of polishing fluid at the tip of the rotating tool to finish workpiece of different materials and shapes. The aim of this research is to study the effect of polishing fluid volume on finishing spot size and the surface finish associated with it. A magnetostatic simulation is done to find the variation of flux density in the working gap and on the workpiece surface. The maximum limit of the polishing fluid volume is selected on the basis of area of threshold magnetic flux density (minimum value required for finishing) region on the workpiece surface. The surface characteristics and the diameter of the finished spot are analyzed by varying the fluid volume. The surface obtained with high fluid volume is poorly finished and has scratch marks as the excess fluid flows out from the working gap and forms a thick ring at the periphery of the tool tip. Contrary to this, if the fluid volume is too less, then it merely rotates over the workpiece surface without causing any finishing action. An optimum range of fluid volume produces a good quality surface finish with constant finished spot size.     

离心式振动抛光装置的设计

设计了一种适用于大长径比异形截面直通道孔腔抛光的振动抛光装置,分析了振动系统的幅频特性,了解了影响抛光装置振幅的主要参数。     

电流变抛光液剪切屈服特性

通过电子显微镜观察了在电场作用下电流变抛光液微粒垂直电极形成的纤维柱状微观结构。根据粒子的结合模型和粒子间的作用力,建立了电流变抛光液的静态剪切屈服应力模型,计算了粒子链的抗剪切强度。在屈服应力测试装置上进行了电流变抛光液的静态剪切屈服应力实验,得到了磨料种类、浓度和粒度对电流变抛光液的剪切屈服应力的影响规律,并通过实验对理论模型进行了验证。     

三头石材磨光机控制系统的设计

针对中小型石材厂在大理石板磨光方面存在设备简陋、工艺落后、生产效率低和产品质量差的问题,以PLC和文本显示器作为核心器件代替传统电器元件设计了三头石材磨光机控制系统。该系统利用三菱FX1N60型PLC进行逻辑控制,利用文本显示器修改参数。现场运行结果表明,系统运行稳定,操作简便,抗干扰能力强,研磨出的石板光泽度比在手扶磨光机上所研磨的光泽度提高20%,该设计已投入运行一年,取得了良好的经济效益,具有较高的推广应用价值。     

Stochastic Models for Pad Structure and Pad Conditioning Used in Chemical-Mechanical Polishing

Stochastic models are presented for the structure and conditioning of pads used in chemical-mechanical polishing of wafers. First the one-dimensional distribution function of surface depth in the case of a conditioned solid pad is described. Then, for characterizing the structure of a foamed pad, the theory of random closed sets is applied. An important distributional characteristic of a random closed set, the linear contact distribution function, yields the contribution to surface depth resulting from pores. As a special example the Boolean model is considered. This leads to a formula that describes the variability of the surface of a conditioned foamed pad after a certain time. Simulations and experimental data show a good agreement between theory and reality.     

一种振动强化抛光装置及其试验

针对传统抛光方式的缺点,设计了一种可利用试件在含磨料液体中振动实现强化抛光加工的装置.这种利用游离态磨粒进行工件的抛光加工的工艺,可获得高的表面质量和表面粗糙度值,而且加工表面无加工变质层.通过正交试验证明加工时间是影响去除量的主要因素,而磨料粒度对表面粗糙度影响较大.试验条件下试件表面粗糙度可达Ra0.10μm,且试件表面的疲劳应力有所提高.从表面状态看,抛光加工后的试件表面并无磨料产生的很长的划痕,只有细密均匀的凹坑.试验证明本装置可对曲面进行强化抛光.     

Influences of polishing on return loss of optical fiber connectors

With Al2O3 and SiO2 as polishing medium, under different polishing conditions, e.g. with different polishing pressure, polishing time and polishing fluid, the influences of polishing treatment on the return loss of optical fiber connectors were investigated. The return loss of optical fiber connectors is 32-38 dB before polishing. The resuits show that dry polishing(i, e. no polishing fluid) with Al2O3 has less influence on return loss of optical fiber connectors, while dry polishing with SiO2 reduces return loss to about 20dB because of the end-face of optical fiber contaminated. The wet polishing(i, e. using distilled water as polishing fluid) with Al2O3 or SiO2 can increase return loss to 45-50dB, but wet polishing with Al2O3 may produce optical fiber undercut depth of 80-140nm. Wet polishing with SiO2 should be preferentially selected for optical fiber connectors and polishing time should be controlled within 20-30s.     

外科植入物用不锈钢金相试样的制备

对外科植入物不锈钢试样的制备进行了试验。结果表明，牙托树脂具有最佳的凝固速度和可填充性，可用手捏成任意的形状，使试样可任意地被压入或被包住，可做到试样镶嵌的随意性，尤其适合细丝和薄板的镶嵌；试面抛光选用非压敏胶植绒型抛光布，抛光效果好，可准确评定夹杂物；选用王水做侵蚀试剂，用擦拭的方法可有效地显示游离铁素体和其显微组织。