Simulation and experimental study on form-preserving capability of bonnet polishing for complex freeform surfaces

Xing Su, Peng Ji, Yuan Jin, Duo Li, David Walker, Guoyu Yu, Hongyu Li, Bo Wang

Research output: Contribution to journalArticle

Abstract

Bonnet polishing has been widely used in structured surface generation, form correction and surface finishing. The inflated flexible tool is able to match the local surface to realize surface finishing. However, after surface finishing, the polishing induced form change is still not clear, especially for complex freeform surfaces with millimeter-level spatial periods. This paper presents a simulation and experimental study on form-preserving capability of bonnet polishing. The concept of form-preserving capability is discussed firstly. Subsequently, the relative surface speed and contact condition on ripple structures are calculated and analyzed. The results demonstrate that the contact condition of bonnet tool on structured surfaces has the main influence on form-preserving capability. Then, the influence of various factors on contact pressure difference is investigated. Compared with experimental results, the linear correlation between form change and the contact pressure difference is obtained, indicating that form-preserving capability can be strengthened by reducing contact pressure difference. Under optimal conditions, the form change can be controlled less than 20 nm, which proves the superior form-preserving capability of bonnet polishing.

Original languageEnglish
Pages (from-to)54-62
Number of pages9
JournalPrecision Engineering
Volume60
Early online date31 Jul 2019
DOIs
Publication statusPublished - 1 Nov 2019

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title = "Simulation and experimental study on form-preserving capability of bonnet polishing for complex freeform surfaces",
abstract = "Bonnet polishing has been widely used in structured surface generation, form correction and surface finishing. The inflated flexible tool is able to match the local surface to realize surface finishing. However, after surface finishing, the polishing induced form change is still not clear, especially for complex freeform surfaces with millimeter-level spatial periods. This paper presents a simulation and experimental study on form-preserving capability of bonnet polishing. The concept of form-preserving capability is discussed firstly. Subsequently, the relative surface speed and contact condition on ripple structures are calculated and analyzed. The results demonstrate that the contact condition of bonnet tool on structured surfaces has the main influence on form-preserving capability. Then, the influence of various factors on contact pressure difference is investigated. Compared with experimental results, the linear correlation between form change and the contact pressure difference is obtained, indicating that form-preserving capability can be strengthened by reducing contact pressure difference. Under optimal conditions, the form change can be controlled less than 20 nm, which proves the superior form-preserving capability of bonnet polishing.",
keywords = "Bonnet polishing, Complex freeform surface, Contact analysis, Form-preserving",
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Simulation and experimental study on form-preserving capability of bonnet polishing for complex freeform surfaces. / Su, Xing; Ji, Peng; Jin, Yuan; Li, Duo; Walker, David; Yu, Guoyu; Li, Hongyu; Wang, Bo.

In: Precision Engineering, Vol. 60, 01.11.2019, p. 54-62.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Simulation and experimental study on form-preserving capability of bonnet polishing for complex freeform surfaces

AU - Su, Xing

AU - Ji, Peng

AU - Jin, Yuan

AU - Li, Duo

AU - Walker, David

AU - Yu, Guoyu

AU - Li, Hongyu

AU - Wang, Bo

PY - 2019/11/1

Y1 - 2019/11/1

N2 - Bonnet polishing has been widely used in structured surface generation, form correction and surface finishing. The inflated flexible tool is able to match the local surface to realize surface finishing. However, after surface finishing, the polishing induced form change is still not clear, especially for complex freeform surfaces with millimeter-level spatial periods. This paper presents a simulation and experimental study on form-preserving capability of bonnet polishing. The concept of form-preserving capability is discussed firstly. Subsequently, the relative surface speed and contact condition on ripple structures are calculated and analyzed. The results demonstrate that the contact condition of bonnet tool on structured surfaces has the main influence on form-preserving capability. Then, the influence of various factors on contact pressure difference is investigated. Compared with experimental results, the linear correlation between form change and the contact pressure difference is obtained, indicating that form-preserving capability can be strengthened by reducing contact pressure difference. Under optimal conditions, the form change can be controlled less than 20 nm, which proves the superior form-preserving capability of bonnet polishing.

AB - Bonnet polishing has been widely used in structured surface generation, form correction and surface finishing. The inflated flexible tool is able to match the local surface to realize surface finishing. However, after surface finishing, the polishing induced form change is still not clear, especially for complex freeform surfaces with millimeter-level spatial periods. This paper presents a simulation and experimental study on form-preserving capability of bonnet polishing. The concept of form-preserving capability is discussed firstly. Subsequently, the relative surface speed and contact condition on ripple structures are calculated and analyzed. The results demonstrate that the contact condition of bonnet tool on structured surfaces has the main influence on form-preserving capability. Then, the influence of various factors on contact pressure difference is investigated. Compared with experimental results, the linear correlation between form change and the contact pressure difference is obtained, indicating that form-preserving capability can be strengthened by reducing contact pressure difference. Under optimal conditions, the form change can be controlled less than 20 nm, which proves the superior form-preserving capability of bonnet polishing.

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