Abstract
Cobalt chrome alloys are the most extensively used biomaterials for manufacturing artificial prostheses, which need nanometer scale surface roughness and micrometer scale form tolerance to extend their lifespan in the tough environment of the human body. In order to machine bearing surfaces to sufficiently high accuracy, the way in which material is removed by the final finishing, such as bonnet polishing, must be completely understood. This study has experimentally investigated the influence of process parameters (precess angle, head speed, tool offset, and tool pressure) on the polishing forces as well as the material removal in bonnet polishing of a medical grade cobalt chrome alloy. Experimental results indicate that normal force increases with the increase in the precess angle, head speed and tool offset, but varies only slightly with the variation of the tool pressure. Tangential force increases with the increase in the precess angle and tool offset while it shows little variation with the change of the head speed and tool pressure. It is concluded that both normal force and tangential force can contribute to the material removal rate, but tangential force is found to be more correlated with the width of the influence function while normal force has a stronger correlation with the maximal height of the influence function.
Similar content being viewed by others
References
Bingham R, Walker D, Kim D, et al. (2000) A novel automated process for aspheric surfaces. In: Proc. SPIE San Diego, CA, USA. pp P445-450
Liu F, Jin Z, Roberts P, Grigoris P (2007) Effect of bearing geometry and structure support on transient elastohydrodynamic lubrication of metal-on-metal hip implants. J Biomech 40(6):1340–1349
Liu C, Wang G, Dargusch M (2012) Modelling, simulation and experimental investigation of cutting forces during helical milling operations. Int J Adv Manuf Technol 63(9–12):839–850. doi:10.1007/s00170-012-3951-4
Tsai C-L, Liao Y-S (2010) Cutting force prediction in ball-end milling with inclined feed by means of geometrical analysis. Int J Adv Manuf Technol 46(5–8):529–541. doi:10.1007/s00170-009-2155-z
Martins Crichigno Filho J (2012) Prediction of cutting forces in mill turning through process simulation using a five-axis machining center. Int J Adv Manuf Technol 58(1–4):71–80. doi:10.1007/s00170-011-3391-6
Amamou R, Ben Fredj N, Fnaiech F (2008) Improved method for grinding force prediction based on neural network. Int J Adv Manuf Technol 39(7–8):656–668. doi:10.1007/s00170-007-1264-9
Turchetta S, Polini W (2011) Cutting force in stone lapping. Int J Adv Manuf Technol 57(5–8):533–539. doi:10.1007/s00170-011-3311-9
Shorey AB, Jacobs SD, Kordonski WI, Gans RF (2001) Experiments and observations regarding the mechanisms of glass removal in magnetorheological finishing. Appl Opt 40(1):20–33
DeGroote JE, Marino AE, Wilson JP, Bishop AL, Lambropoulos JC, Jacobs SD (2007) Removal rate model for magnetorheological finishing of glass. Appl Opt 46(32):7927–7941
Miao C, Lambropoulos JC, Jacobs SD (2010) Process parameter effects on material removal in magnetorheological finishing of borosilicate glass. Appl Opt 49(10):1951–1963
Sidpara A, Jain VK (2011) Experimental investigations into forces during magnetorheological fluid based finishing process. Int J Mach Tool Manuf 51(4):358–362
Sidpara A, Jain VK (2012) Theoretical analysis of forces in magnetorheological fluid based finishing process. Int J Mech Sci 56(1):50–59. doi:10.1016/j.ijmecsci.2012.01.001
Sidpara A, Jain VK (2013) Analysis of forces on the freeform surface in magnetorheological fluid based finishing process. Int J Mach Tool Manuf 69(0):1–10. doi:10.1016/j.ijmachtools.2013.02.004
Homma Y, Fukushima K, Kondo S, Sakuma N (2003) Effects of mechanical parameters on CMP characteristics analyzed by two-dimensional frictional-force measurement. J Electrochem Soc 150(12):G751–G757
Tsai H-J, Huang P-Y, Tsai H-C, Chiu S-J (2011) Chemical mechanical polishing in elastic contact and partial hydrodynamic lubrication: modeling and experiments. Mater Manuf Process 26(2):319–324. doi:10.1080/10426914.2010.544956
Walker DD, Beaucamp AT, Bingham RG, et al. (2004) Precessions aspheric polishing: new results from the development program. In: Optical science and technology, SPIE's 48th Annual Meeting. International Society for Optics and Photonics, pp 15–28
Preston FW (1927) The theory and design of glass plate polishing machine. Journal of the Society of Glass Technology 11 (247)
Zeng S, Blunt L, Jiang X (2012) The investigation of material removal in bonnet polishing of CoCr alloy artificial joints. In: 12th International conference of Euspen, Stockholm. EUSPEN, pp 352–355
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zeng, S., Blunt, L. An experimental study on the correlation of polishing force and material removal for bonnet polishing of cobalt chrome alloy. Int J Adv Manuf Technol 73, 185–193 (2014). https://doi.org/10.1007/s00170-014-5801-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-5801-z