Skip to main content
SpringerLink
Log in

Arc Envelope Grinding of Sapphire Steep Aspheric Surface with SiC-Reinforced Resin-Bonded Diamond Wheel

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing-Green Technology Aims and scope Submit manuscript

Abstract

In order to improve the grinding wheel wear during the sapphire steep aspheric surface grinding process, a SiC-reinforced resin-bonded hemispherical diamond wheel was used and the arc envelope grinding performance was investigated. Firstly, the mapping relationship between the contours of the grinding wheel and the aspheric surface was established based on the grinding conditions. The wear of the hemispherical diamond wheel was modelled, and the result indicates that the maximum wear occurred at the edge of the hemisphere, decreases along the generatrix and increases near the center. Then, the form-trued diamond wheel was used for grinding the sapphire steep aspheric surface. The concave and convex surface form error obtained at the central part of Φ 50 mm are 2.5 μm and 1.3 μm, respectively. The surface roughness Ra is 230–450 nm, which is affected by the material removal rate and the sapphire crystal anisotropy. The SiC-reinforced resin-bonded diamond wheel possesses favorable self-sharpening ability and sufficient diamond grain retention capacity for sapphire grinding. The wear distribution shows that the most severe wear parts of the grinding wheel are at the edge and the center of the grinding zone, which is consistent with the model-predicted results.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15

Similar content being viewed by others

Abbreviations

R :

Aspheric surface paraxial radius of curvature

K :

Conic constant

C i :

Coefficients of the aspheric surface

β :

Inclination angle of tool spindle

S v :

Surface area of wheel that participated in grinding

r t :

Radius of hemispherical diamond wheel

Δl w :

Arc length increment of grinding trajectory on the aspheric surface

Δl t :

Arc length increment of grinding trajectory on the wheel surface

\(\bar{K}\) :

Mean curvature corresponding to Δlw

ρ w :

Radius of curvature along the aspheric surface generatrix

θ′:

Turned angle of the grinding point on the wheel contour

θ″:

Turned angle of the grinding point on the aspheric surface generatrix

Δl t″:

Generatrix length of aspheric surface corresponding to Δθ″

k wt :

Ratio of Δlw and Δlt″

G :

Grinding ratio

dV w :

Volume differential element of the material removal

dV t :

Volume differential element of the grinding wheel wear

dl w :

Differential arc-length on the aspheric surface corresponding to dVw

dl t :

Differential length of grinding trajectory on the wheel surface corresponding to dVt

dl t″:

Differential length along the aspheric surface generatrix corresponding to dlt

a p :

Grinding depth

a w :

Grinding wheel wear depth

References

  1. Wegener, K., Bleicher, F., Krajnik, P., Hoffmeister, H. W., & Brecher, C. (2017). Recent developments in grinding machines. CIRP Annals, 66(2), 779–802.

    Article  Google Scholar 

  2. Wang, Z., Yan, Y., Zhou, P., Si, L., Kang, R., & Guo, D. (2018). A high-efficient precision grinding for fabricating moderately thick plane mirror (MTPM). The International Journal of Advanced Manufacturing Technology, 96(5–8), 2559–2566.

    Article  Google Scholar 

  3. Chen, B., Li, S., Deng, Z., Guo, B., & Zhao, Q. (2017). Grinding marks on ultra-precision grinding spherical and aspheric surfaces. International Journal of Precision Engineering and Manufacturing-Green Technology, 4(4), 419–429.

    Article  Google Scholar 

  4. Wang, T., Cheng, J., Liu, H., Chen, M., Wu, C., & Su, D. (2019). Ultra-precision grinding machine design and application in grinding the thin-walled complex component with small ball-end diamond wheel. The International Journal of Advanced Manufacturing Technology, 101(5–8), 2097–2110.

    Article  Google Scholar 

  5. Brinksmeier, E., Preuss, W., Riemer, O., & Rentsch, R. (2017). Cutting forces, tool wear and surface finish in high speed diamond machining. Precision Engineering, 49, 293–304.

    Article  Google Scholar 

  6. Feng, M., Wu, Y., Wang, Y., Zeng, J., Bitoh, T., Nomura, M., et al. (2020). Investigation on the polishing of aspheric surfaces with a doughnut-shaped magnetic compound fluid (MCF) tool using an industrial robot. Precision Engineering, 61, 182–193.

    Article  Google Scholar 

  7. Kuriyagawa, T., Zahmaty, M. S. S., & Syoji, K. (1996). A new grinding method for aspheric ceramic mirrors. Journal of Materials Processing Technology, 62(4), 387–392.

    Article  Google Scholar 

  8. Chen, F., Yin, S., Huang, H., & Ohmori, H. (2015). Fabrication of small aspheric moulds using single point inclined axis grinding. Precision Engineering, 39, 107–115.

    Article  Google Scholar 

  9. Hallock, B., & Shorey, A. (2009). Technologies for precision manufacture of current and future windows and domes. Window and Dome Technologies and Materials XI. International Society for Optics and Photonics, 7302, 73020V.

    Google Scholar 

  10. Fess, E., DeFisher, S., Cahill, M., & Wolfs, F. (2015). Development of manufacturing technologies for hard optical ceramic materials. Window and Dome Technologies and Materials XIV. International Society for Optics and Photonics, 9453, 94530C.

    Google Scholar 

  11. DeFisher, S., Fess, E., & Wolfs, F. (2013). Freeform and conformal optical manufacturing. Window and Dome Technologies and Materials XIII International Society for Optics and Photonics, 8708, 870813.

    Google Scholar 

  12. Chen, B., Guo, B., & Zhao, Q. (2015). An investigation into parallel and cross grinding of aspheric surface on monocrystal silicon. The International Journal of Advanced Manufacturing Technology, 80(5–8), 737–746.

    Article  Google Scholar 

  13. Fess, E., & DeFisher, S. (2013). Advancements in asphere manufacturing. Optical Manufacturing and Testing X. International Society for Optics and Photonics, 8838, 88380M.

    Article  Google Scholar 

  14. Wang, T., Wu, C., Liu, H., Chen, M., Cheng, J., Fang, Z., et al. (2019). Configuration design and accuracy analysis of special grinding machine for thin-walled small concave surfaces. Precision Engineering, 56, 293–302.

    Article  Google Scholar 

  15. Liu, L., & Zhang, F. (2017). Prediction model of form error influenced by grinding wheel wear in grinding process of large-scale aspheric surface with SiC ceramics. The International Journal of Advanced Manufacturing Technology, 88(1–4), 899–906.

    Article  Google Scholar 

  16. Li, Y., Funkenbusc, P. D., Gracewski, S. M., & Ruckman, J. (2004). Tool wear and profile development in contour grinding of optical components. International Journal of Machine Tools and Manufacture, 44(4), 427–438.

    Article  Google Scholar 

  17. Li, W., Ren, Y., Li, C., Li, Z., & Li, M. (2019). Investigation of machining and wear performance of various diamond micro-grinding tools. The International Journal of Advanced Manufacturing Technology, 106(3–4), 921–935.

    Article  Google Scholar 

  18. Azarhoushang, B., & Ludwig, S. (2019). In-process grinding wheel wear evaluation using digital image processing. International Journal of Abrasive Technology, 9(2), 99–112.

    Article  Google Scholar 

  19. Xu, L. M., Fan, F., Zhang, Z., Chao, X. J., & Niu, M. (2019). Fast on-machine profile characterization for grinding wheels and error compensation of wheel dressing. Precision Engineering, 55, 417–425.

    Article  Google Scholar 

  20. Guo, B., & Zhao, Q. (2017). Ultrasonic vibration assisted grinding of hard and brittle linear micro-structured surfaces[J]. Precision Engineering, 48, 98–106.

    Article  Google Scholar 

  21. Yan, G., You, K., & Fang, F. (2019). Three-linear-axis grinding of small aperture aspheric surfaces[J]. International Journal of Precision Engineering and Manufacturing-Green Technology. https://doi.org/10.1007/s40684-019-00103-7.

    Article  Google Scholar 

  22. Zhang, Z., Yang, X., Zheng, L., & Xue, D. (2017). High-performance grinding of a 2-m scale silicon carbide mirror blank for the space-based telescope. The International Journal of Advanced Manufacturing Technology, 89(1–4), 463–473.

    Article  Google Scholar 

  23. Wang, J., Zhao, Q., Zhang, C., Guo, B., & Yuan, J. (2020). On-machine precision form truing and in situ measurement of resin-bonded spherical diamond wheel. Applied Sciences, 10(4), 1483.

    Article  Google Scholar 

  24. Voloshin, A. V., Litvinov, L. A., & Slyunin, E. V. (2013). The influence of sapphire crystallographic orientation on surface roughness achievable by diamond abrasive machining. Journal of Superhard Materials, 35(1), 56–59.

    Article  Google Scholar 

  25. Wang, J., Guo, B., Zhao, Q., Zeng, Z., Zhai, W., Chen, H., et al. (2019). Investigation into the anisotropy of cross-grinding surface quality in C-and M-planes of sapphire. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 233(1), 44–54.

    Article  Google Scholar 

  26. Wang, J., Guo, B., Zhao, Q., Zhang, C., Zhang, Q., Chen, H., et al. (2017). Dependence of material removal on crystal orientation of sapphire under cross scratching. Journal of the European Ceramic Society, 37(6), 2465–2472.

    Article  Google Scholar 

  27. Zhang, Q., To, S., Zhao, Q., & Guo, B. (2016). Surface damage mechanism of WC/Co and RB-SiC/Si composites under high spindle speed grinding (HSSG). Materials and Design, 92, 378–386.

    Article  Google Scholar 

Download references

Acknowledgements

This research work is supported by the National Natural Science Foundation of China [Grant nos. 51805484 and 51875135], and the China Postdoctoral Science Foundation [Grant no. 2019M652137].

Author information

Authors and Affiliations

  1. Ultra-Precision Machining Center, College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China

    Jinhu Wang & Julong Yuan

  2. Center for Precision Engineering, School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, China

    Qingliang Zhao & Bing Guo

  3. Research Center of Laser Fusion, China Academy of Engineering Physics, Mianyang, 621900, China

    Chunyu Zhang

Authors
  1. Jinhu Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Qingliang Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chunyu Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Bing Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Julong Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jinhu Wang.

Ethics declarations

Conflict of interest

On behalf of all authors, the corresponding author states that there is no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, J., Zhao, Q., Zhang, C. et al. Arc Envelope Grinding of Sapphire Steep Aspheric Surface with SiC-Reinforced Resin-Bonded Diamond Wheel. Int. J. of Precis. Eng. and Manuf.-Green Tech. 8, 1083–1094 (2021). https://doi.org/10.1007/s40684-020-00225-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40684-020-00225-3

Keywords

Search

Navigation