Axicon Cone Surface Finishing With Oscillating Abrasive Contact
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Solution Overview
Problem
Existing methods for fine-processing axicons often result in undesired surface faults and high surface roughness due to radial predominant removal effects, which are challenging to avoid, especially in high-precision applications requiring RMSi values of ≤0.7 μm or less.
Innovation Solution
A method involving a tool with geometrically indeterminate cutting edges that uses a combination of rotational movement of the axicon and oscillating linear movement of the tool relative to the cone surface, ensuring the tool's front end moves radially back and forth, thereby avoiding radial groove structures and allowing for high removal performance and precise angle correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a diametrally smaller polishing tool with conical circumferential surface is used, then the conical surface can be processed to finished state, but radial groove structures and high surface roughness occur due to radial predominant removal effects
Solution Approach 1:
The patent applies ultrasonic vibration to the polishing tool at frequencies between 20-100 kHz with amplitudes of 1-10 μm. This vibration superimposes on the rotational movement, transforming the radial predominant removal into a more uniform material removal pattern that eliminates radial groove structures while maintaining high surface quality
Solution Approach 2:
The patent implements periodic oscillating movement of the polishing tool in addition to continuous rotation. The tool performs reciprocating linear movements along the cone surface with controlled frequencies and amplitudes, creating periodic contact patterns that prevent radial groove formation and achieve uniform surface finishing
2Productivity
If conventional polishing methods are used, then material removal can be achieved, but processing time is extended and surface roughness increases
Solution Approach 1:
Ultrasonic vibration enhances the material removal rate by creating micro-impact effects that accelerate abrasion. The high-frequency oscillations (20-100 kHz) with amplitudes of 1-10 μm break down material more efficiently, reducing processing time while simultaneously producing smoother surfaces by preventing radial groove structures
Solution Approach 2:
The patent transforms the static polishing contact into a dynamic process by superimposing ultrasonic vibration and oscillating movements on the rotational polishing. This dynamic approach allows the tool to interact with the workpiece in a time-varying manner, increasing material removal efficiency and surface quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables high-quality fine-processing of axicons with reduced surface roughness and angle errors, achieving faster processing times and improved surface quality without the formation of undesired structures.
Implementation Method 1
with use of geometrically indeterminate cutting edges in the form of bound or loose grain in combination with a liquid at the processing region of the tool there is produced a material removal
Data Source
AI summary
In a method for fine-processing of an axicon (L) having a concave or convex cone surface (KF) with a cone axis (KA) and a cone angle (α), with use of geometrically indeterminate cutting edges in the form of grain in combination with a liquid at a processing region (BB) of a tool (W2), which is constructed for linear engagement (LE) with the cone surface and has a front end (EB) with respect to the cone axis, material removal is produced at the cone surface by a relative cutting speed which results from a rotational movement of the axicon about the cone axis and a relative oscillating linear movement (oscillation axis R) of the tool, in which the processing region is disposed in linear engagement with the cone surface and its front end moves back and forth in a direction radial with respect to the cone axis.