scholarly journals Study of the Transcription Effects of Pressing Dies with Ultrasonic Polishing on Glass Molding

Processes ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 2083
Author(s):  
Ken-Chuan Cheng ◽  
Chien-Yao Huang ◽  
Jung-Chou Hung ◽  
A-Cheng Wang ◽  
Yan-Cherng Lin
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Sine Wave ◽  
Optical Systems ◽  
Lens Array ◽  
Glass Molding ◽  
Good Surface ◽  
Good Surface Roughness ◽  
Micro Lens Array

The micro lens array (MLA) has played an important role in optical systems for the past few years, and the precision of pressing dies has dominated the quality of MLAs in glass molding. Few studies have covered the transcription effects on surface roughness of pressing dies for this technology. Therefore, this research utilized pressing dies to produce a sine-wave lens array on glass molding, to transform the Gauss-distributed spotlight into a uniform straight one and then characterize the transcription effects of these lenses. Pressing dies with a sine-wave shape were firstly cut by wire electrical discharge machining (WEDM), and then ultrasonic polishing using diamond abrasives was applied to finish the sine-wave surface with an original roughness of 0.2 μm Ra. Next, the sine-wave lens arrays were pressed by glass molding at the appropriate pressure and temperature, before evaluating the transcription effects of transforming the Gauss-distributed spotlight into a uniform straight one. The result showed that the sine-wave lens array stuck easily to the pressing die and then ruptured during glass molding due to the poor surface roughness of pressing tool. However, the diamond abrasive with appropriate sizes could establish good surface roughness on pressing dies via ultrasonic polishing, and the pressing die with a low surface roughness of 0.08 μm Ra was able to successfully perform MLA in the glass molding. However, only pressing dies with a surface roughness smaller than 0.023 μm Ra could produce precision glass lenses to transform the Gauss-distributed spotlight into a uniform straight one.

scholarly journals Analysis of Surface Roughness Value When Drilling Magnesiumaz31 Using Taghuci Method

INSIST ◽  
2019 ◽  
Vol 2 (2) ◽  
pp. 71
Author(s):  
Gusri Akhyar Ibrahim ◽  
Arinal Hamni ◽  
Sri Maria Puji Lestari
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Taguchi Method ◽  
Feed Rate ◽  
Workpiece Material ◽  
Machined Surface ◽  
Good Surface ◽  
Good Surface Roughness ◽  
Experimental Trials

Magnesium alloy is one of super alloys material which wide used in manufacturing of automotive, biomedic, sport and electronic components. It was due to very light and resistent to corrosion. Surface roughness value has an important role to estabilish the quality of components. To produce a good surface roughness of machined surface, one of the important thing depends on the friction between the cutting tool and workpiece material when cutting process occurred. The aim of this paper is to analyse the surface roughness values of machined surface when drilling of magnesium alloy AZ31 using design of experiment of Taguchi Method. The experimental trials took place at cutting rotation of 635, 970 and 1420 rpm, feed rate of 0.10, 0.18 and 0.24 mm/rev, diameter tool of 10, 12 and 14 mm. The cutting of magnesium alloy was done by using a convensional drilling machine with TCA –35Erlo. Analysis of variance on the data of surface roughness value was done to get which factor is the most significant. The result shows that the feed rate is the most significant factor that contributed on the surface rougness value of machined surface. The minimum surface roughness value was attained at cutting rotation of 970 rpm, feed rate of 0.10 mm/rev and diameter of tool of 14 mm. Therefore, it can be stated that selecting the low feed rate factor produced low surface roughness value. Another hand, using high cutting rotation resulted low surface roughness value.Keywords—drilling, surface roughness, magnesiun AZ31,Taguchi Method

Comparison of Processing Features between Semi Bonded Abrasive Lapping and Loose Abrasive Lapping

2009 ◽  
Vol 416 ◽  
pp. 439-442
Author(s):  
Xun Lv ◽  
Ju Long Yuan ◽  
Dong Hui Wen
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Processing Parameters ◽  
Good Surface ◽  
Ultra Precision ◽  
New Processing ◽  
Short Time

Semi bonded abrasive lapping is an effective ultra-precision lapping method. It can obtain good surface quality of workpiece in short time. This paper focused on the differences of processing features by comparing semi bonded abrasive lapping and loose abrasive lapping in several groups processing parameters. The results showed that the surface roughness of workpiece in semi bonded abrasive lapping was far superior to that of loose abrasive lapping in same processing parameters. And the MRR (material removal rate) of semi bonded abrasive lapping was slightly lower than that of loose abrasive lapping. For these features of semi bonded abrasive, a new processing flow would also be proposed in this paper.

scholarly journals Surface Roughness Models and Their Experimental Validation in Micro Milling of 6061-T6 Al Alloy by Response Surface Methodology

2015 ◽  
Vol 2015 ◽  
pp. 1-9 ◽  
Author(s):  
Jie Yi ◽  
Li Jiao ◽  
Xibin Wang ◽  
Junfeng Xiang ◽  
Meixia Yuan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Removal Rate ◽  
Micro Milling ◽  
Al Alloy ◽  
Machined Surface ◽  
Contour Map ◽  
Good Surface ◽  
Micro Features ◽  
Good Surface Roughness

Due to the widespread use of high-accuracy miniature and micro features or components, it is required to predict the machined surface performance of the micro milling processes. In this paper, a new predictive model of the surface roughness is established by response surface method (RSM) according to the micro milling experiment of 6061-T6 aluminum alloy which is carried out based on the central composite circumscribed (CCC) design. Then the model is used to analyze the effects of parameters on the surface roughness, and it can be concluded that the surface roughness increases with the increasing of the feed rate and the decreasing of the spindle speed. At last, based on the model the contour map of the surface roughness and material removal rate is established for optimizing the process parameters to improve the cutting efficiency with good surface roughness. The prediction results from the model have good agreement with the experimental results.

Surface Roughness in High Feed Turning with Wiper Insert

2008 ◽  
Vol 375-376 ◽  
pp. 406-410 ◽  
Author(s):  
Zhan Qiang Liu ◽  
Peng Zhang ◽  
Peng Guo ◽  
Xing Ai
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Machined Surface ◽  
Good Surface ◽  
Corner Radius ◽  
Number Of Factors ◽  
Machined Surface Roughness ◽  
High Feed ◽  
Good Surface Roughness ◽  
Coated Carbide

Surface roughness in a turning operation is affected by a great number of factors. Two of the most important factors are feed rate and the size of the corner radius. Surface roughness can be roughly determined to increase with the square of the feed rate and decrease with increased size of the corner radius. However, wiper insert geometries changed this relationship with the capability to generate good surface roughness at relatively higher feeds by transferring small part of the round insert edges into the straight cutting edges of the pointed insert. The principle of how wiper inserts behave different from conventional inserts as to the effects on the surface roughness is explored in this paper. Experimental study of the surface roughness produced in the turning of hardened mild steels using coated carbide tools with both conventional and wiper inserts is conducted. The test results prove the effectiveness of the wiper inserts in providing excellent surface roughness. The results also suggest that the use of the wiper insert is an effective way that significantly increases cutting efficiency without changing the machined surface roughness in high feed turning operations.

Proposal of Finishing Method of MLA Mold Applied Sphere Indentation

2013 ◽  
Vol 797 ◽  
pp. 475-480
Author(s):  
Yasunori Kobayashi ◽  
Ryo Ishida ◽  
Haruhisa Sakamoto
Keyword(s):  
Surface Roughness ◽  
Early Stage ◽  
The Novel ◽  
Lens Array ◽  
Finished Surface ◽  
Improvement Effect ◽  
Micro Lens Array ◽  
Micro Lens ◽  
Previous Step ◽  
The Ideal

In this study, the novel finishing method of the Micro Lens Array mold is proposed. This method combines the cutting by a ball-endmill and the finishing by sphere indentation. In the previous step, U-shape grooves intersected at right angle are machined by a ball-endmill. In the following step, the ball tool indents at the intersection between U-shape grooves, consequently, the aiming lens form and the aiming surface roughness are obtained. From the results of the manufacturing experiments of the MLA mold by this method, the following are made clear : The proposed method is effective to suppress the deformation of neighboring lens forms caused by following indentation. The improvement effect of sphere indentation on the finished surface roughness is remarkable in the early stage of indentation. The transcribing deviations are 12μm or less in comparison between the radius of lens form and the ideal value regardless of radii in grooves previously cut. In case of the indentation of neighboring four (2 × 2) lenses, the deviation reduces down to 3μm.

Polishing Experiment Study of the Elastic Coated Abrasives

2014 ◽  
Vol 941-944 ◽  
pp. 1981-1984
Author(s):  
Gui Lian Wang ◽  
Hai Bo Zhou ◽  
Shu Li Guo ◽  
De Chen Huang ◽  
Ren Bao Jiao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Efficiency ◽  
Future Research ◽  
Workpiece Material ◽  
Good Surface ◽  
Aisi 1045 Steel ◽  
Good Surface Roughness ◽  
1045 Steel ◽  
Polishing Efficiency ◽  
Coated Abrasives

A kind of elastic coated abrasives used for polishing large mould surface, such as automobile panel mould, is investigated in this research. Many polishing experiments were finished by using elastic coated abrasives in order to study the effects of grit and workpiece material on surface roughness and machining efficiency. It is concluded that surface roughness is minimum and polishing efficiency is the highest when using 120# abrasives at the same condition, surface roughness is the lowest and polishing efficiency is the highest for AISI 1045 steel in three materials. The difficulty of material removal is different if the textures prior to polishing are different in workpiece surface. Surface texture prior to polishing has effects on surface roughness and polishing efficiency. The research results provide foundation for process planning to achieve good surface roughness and high efficiency in the future research.

scholarly journals Influence of Ultrasonic Burnishing Technique on Surface Quality and Change in the Dimensions of Metal Shafts

2014 ◽  
Vol 2014 ◽  
pp. 1-8 ◽  
Author(s):  
Juha Huuki ◽  
Mikael Hornborg ◽  
Jermu Juntunen
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Surface Hardness ◽  
Modern Method ◽  
Processing Times ◽  
Good Surface ◽  
Rotating Shafts ◽  
Mechanical Surface ◽  
Reduced Surface

This paper presents ultrasonic burnishing as a mechanical surface treatment for improving the quality of rotating shafts. Ultrasonic burnishing is a modern method for finishing workpieces to produce a good surface quality. This process improves the surface quality and increases the surface hardness of the workpiece, and the surface roughness of the workpiece improves. As a result, wear resistance and fatigue life increase. Furthermore, these improvements are achieved without expensive equipment or long processing times. In this paper the influence of the ultraburnishing technique on the change in diameter and its effects on the out-of-roundness of rotating shafts are investigated. This paper also takes a look at the magnitudes of the improvement of the surface roughness as a result of using ultrasonic burnishing. Three different materials, aluminium, 34-CrNiMo6 tempering steel, and S355J2 structural steel, are examined. The results showed that ultrasonic burnishing is a treatment that improves the quality of components. Ultrasonic burnishing also has a reducing effect on the final diameter and out-of-roundness and increases the hardness of the workpiece. It can also be stated that the material of the workpiece does not have a significant effect on the magnitude of the reduced surface roughness values.

Effects of abrasive types on the surface integrity of abrasive-flow-machined surfaces

2016 ◽  
Vol 232 (6) ◽  
pp. 1044-1053 ◽  
Author(s):  
Kursad Gov ◽  
Omer Eyercioglu
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
White Layer ◽  
Machining Process ◽  
Wire Electrical Discharge Machining ◽  
Abrasive Flow Machining ◽  
The Media ◽  
Surface Improvement

In this article, the effect of abrasive types on the abrasive flow machining process was investigated. Four groups of abrasive media were prepared with different types of abrasives: SiC, AL2O3, B4C and Garnet. An experimental study was performed on DIN 1.2379 tool steel. The specimens were cut using wire electrical discharge machining and finished with the abrasive flow machining process. The results show that the white layer that formed during wire electrical discharge machining was successfully removed by abrasive flow machining in a few cycles. Although the surface roughness improves with similar trends for all media groups, the results show that the media prepared with B4C and SiC have more surface improvement than the Al2O3 and Garnet ones. The resulting average surface roughness (Ra) values are comparable to the surface quality of those obtained from lapping and super-finishing. The material removal is directly related to the hardness of the abrasive.

Wear Behavior of B4C reinforced Al6063 matrix composites electrode fabricated by stir casting method

2020 ◽  
Author(s):  
MATHALAI SUNDARAM C ◽  
Radha Krishnan B ◽  
HARIKISHORE S ◽  
V. Vijayan
Keyword(s):  
Surface Roughness ◽  
Electrical Discharge Machining ◽  
Wear Behavior ◽  
Casting Process ◽  
Surface Characteristics ◽  
Stir Casting ◽  
Composite Electrodes ◽  
Die Steel ◽  
Hardness Tester ◽  
Good Surface

The aim of the study is to predict the surface topological characteristics of Al-B4C composite electrodes and the OHNS Die steel in the Electrical Discharge Machining (EDM) Process. The surface characteristics of Composite electrodes are evaluated by using Scanning Electron Microscopy (SEM) and EDAX Analytical Method. Surface roughness and hardness of the OHNS die steel was measured by the Stylus probe and Brinnel hardness. The composite electrodes prepared by the Aluminium 6063 and B4C materials. Both elements are mixed at molten state in the stir casting process at different compositions. The chemical composition properties of the Composite electrode is analyzed by the SEM and EDAX testing. The surface Roughness of the OHNS steel measured by the Brinell hardness tester. Based on the SEM and EDAX results, the 92% Al 8% B4C was producing the good surface roughness in OHNS die steel.

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