The application of Taguchi approach to optimise the processing conditions on bonnet polishing of CoCr

This paper applied the Taguchi approach to investigate the effects of each polishing parameter and obtain the optimal processing conditions for CoCr alloy polishing. The polishing medium was 1µm diamond paste with Microcloth(polishing cloth). Surface finish parameter Sa was chosen as criterion for optimization. The experimental result indicates that the optimal polishing condition for CoCr alloy polishing is 5deg of precess angle, 800 rpm of head speed, 0.2mm of tool offset and 1.5 bar of tool pressure. With this optimal condition, a confirmatory experiment was conducted. The surface roughness Sa reduced from initial 24nm to 7nm and reduction ratio was 72.5% which was very close to the estimated ratio 64%

Material removal investigation in bonnet polishing of CoCr alloy

The manufacture of orthopaedic joint bearings surfaces requires exceptionally high levels of control of not only the surface finish but also the surface form. In the case of hip joints, the form of femoral head should be controlled to within ± 50ìm from a given diameter. It has been shown that a better form control of bearing component could enhance clearances creating the correct volume of lubrication to fill the bearing surface gap and reduce wear particle generation. This element is especially critical for the new generation non-spherical head designs. Bonnet polishing which is used successfully in the area of optics is potentially an excellent finishing process to control the form and finish of artificial joints. In the process of form control polishing an “influence function” which defines the material removal rate is of vital importance in developing a corrective polishing procedure. However, the effects of polishing parameters (such as precess angle, head speed, tool pressure and tool offset) on influence function are not very clear for CoCr alloys. These elements must be assessed if a deterministic polishing process is to be developed. Therefore, it is of paramount importance to understand the contribution of each polishing factors to influence function and consequent part polishing. This study has investigated the effects of polishing parameters on influence function, including geometric size and volumetric material removal rate (MRR). The experimental results indicate that the polishing parameter of precess angle and tool offset affect the geometric size of influence function significantly; the polishing parameter of head speed and tool pressure affect the geometric size of influence function to a lesser degree; the polishing parameter of precess angle, head speed and tool offset affect MRR greatly

Acid Polishing of Lead Crystal Glass

The industrial partner manufactures high quality lead crystal glassware. The cutting of decorative features in the glass damages the surface and the cuts are optically opaque; to restore transparency, the glass is polished in a solution of hydrofluoric (HF) and sulphuric acid (H2 SO4 .) The polishing process comprises three stages: 1. immersion in a polishing tank containing acid; 2. rinsing in a tank containing water; and 3. settlement of the solid reaction products in a settlement tank. The manufacturer hopes to optimise its polishing process to • minimise the health/environmental impact of the process; • maximise throughput; • maintain the sharpness of the cut edges while still polishing to an acceptable level of transparency. The study group was asked to focus on modelling three aspects of the process: • the chemical reactions involved in the etching at the glass-acid solution interface; • the removal of reaction products in the settlement tank; • flow within the polishing tank

MODIFIKASI CASING PIRINGAN PEMOLES DAN SEKAT BAK SIRKULASI AIR

Casing polishing disc on a polishing machine consists of four parts, there are: (a) upper Casing. (B) outter tube plate. (C) inner tube plate. (C) base tube. Tub’s bulkhead of water circulation serves as a separator between the tub and the water entrance of the first chamber to chamber through the septum into two parts on the deposition system. The modification of Polishing disk and tub’s bulkhead of water circulation is to: (1) Knowing the process of modification of Polishing disk and tub’s bulkhead of water circulation. (2) Knowing the equipment required in the modification of polishing disk and tub’s bulkhead of water circulation. (3) Knowing the modified Polishing disk and tub’s bulkhead of water circulation after the performance test. The method used in the modification of polishing disk and tub’s bulkhead of water circulation include: Identification of working drawings, material identification, machine identification, the identification of the tools used and Safety matter. The order of the manufacturing process include: material selection, material preparation, perforation of materials, formation, splicing, and surface settlement. Materials used for modified casing and seal plate polishing bath is eyzer plate 1 and 2 mm thick. Based on the achievements of the whole process modification and testing can be summarized as follows: (1) The process of polishing disc casing modifications include: Identification of working drawings, material identification, machine identification, identification of the tools used and Safety matter. Sequence modification process include: material selection, material preparation, perforation of materials, the formation, continuation, and completion of the surface. (2) Machinery, equipment and tools used are: gullotine hydraulic machines, lever shears, hand shears, drilling machines and accessories, compressor grinding machines, welding set ÖAW, plate bending tool, tool roller plate, roll bar, steel bar, the right angle bar, etcher, rasp hand tool, steel hammer, plastic hammer, strike pad, right angle ruler and pliers. (3) The results of performance testing of polishing disc casing include: all parts of the casing to function properly, causing no noise during operation and gives interesting look at the engine. The results of performance test of tub’s bulkhead, the bulkhead well functioned and capable of producing clean water that is ready to re-use in the polishing process. There is a difference between the size of the working drawings to the finished object. The size difference does not affect test performance. The difference in size results an error percentage, the percentage of errors on the casing polishing by 0.99% and the percentage of errors on the tub’s bulkhead water circulation of 1.84%

Automatic polishing process of plastic injection molds on a 5-axis milling center

The plastic injection mold manufacturing process includes polishing operations when surface roughness is critical or mirror effect is required to produce transparent parts. This polishing operation is mainly carried out manually by skilled workers of subcontractor companies. In this paper, we propose an automatic polishing technique on a 5-axis milling center in order to use the same means of production from machining to polishing and reduce the costs. We develop special algorithms to compute 5-axis cutter locations on free-form cavities in order to imitate the skills of the workers. These are based on both filling curves and trochoidal curves. The polishing force is ensured by the compliance of the passive tool itself and set-up by calibration between displacement and force based on a force sensor. The compliance of the tool helps to avoid kinematical error effects on the part during 5-axis tool movements. The effectiveness of the method in terms of the surface roughness quality and the simplicity of implementation is shown through experiments on a 5-axis machining center with a rotary and tilt table

Roughness evolution of previously milled samples along a polishing test

In the present work results about roughness evolution along a polishing operation with corundum disks of size Norton 400 are presented. Hardened steel and hardened stainless steel samples were previously subjected to ball-end milling or side milling with cylindrical tool at different cutting conditions. Roughness height parameters Ra and Rt, as well as parameters related to the Abbott-Firestone curve such as Rk, Rpk, and Rvk, and shape parameters such as Rsk and Rku were studied. It is usually considered that a polishing operation is complete when Ra does not decrease significantly with more polishing time. In the present paper, an alternative method for determining the end of a polishing test is presented. Roughness is measured both in the longitudinal and in the transversal direction with respect to cutting marks, and it is assumed that the polishing operation is finished when longitudinal values equal transversal values, provided that from that moment on roughness values do not decrease significantly. Moreover, it is recommended to measure parameter Rvk in addition to or even instead of Ra, in order to obtain information about the presence of valleys from the previous milling operation.Postprint (author's final draft

Influence of different polishing materials in the material removal of steel samples

The quality of injection moulded polymer optic parts depends on the surface finish of the respective mould. In order to improve and control the surface finish of the mould it is important to be able to keep the material removal constant during the polishing process of these moulds. This will provide a tactical material removal therefore allowing a controlled correction of the mould’s surface geometry. The aim of this work is to study the influence of different polishing materials in the material removal rate and its reproducibility during the polishing process of hardened steel. Different polyurethane polishing materials with different fillers were tested. It was observed that the filler material of the polyurethane is crucial in order to obtain constant and reproducible results. Experiments were carried out with an industrial robot and the material removal’s depth value was compared

Ultrasonic Polishing

The ultrasonic polishing process makes use of the high-frequency (ultrasonic) vibrations of an abradable tool which automatically conforms to the work piece and an abrasive slurry to finish surfaces and edges on complex, highly detailed, close tolerance cavities in materials from beryllium copper to carbide. Applications range from critical deburring of guidance system components to removing EDM recast layers from aircraft engine components to polishing molds for forming carbide cutting tool inserts or injection molding plastics. A variety of materials including tool steels, carbides, and even ceramics can be successfully processed. Since the abradable tool automatically conforms to the work piece geometry, the ultrasonic finishing method described offers a number of important benefits in finishing components with complex geometries