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Configuration design and accuracy analysis of a novel magnetorheological finishing machine tool for concave surfaces with small radius of curvature

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Abstract

Magnetorheological finishing (MRF) is a computer-controlled deterministic polishing technique that is widely used in the production of high-quality optics. In order to overcome the defects of existing MRF processes that are unable to achieve concave surfaces with small radius of curvature, a configuration method of a novel structured MRF machine tool using small ball-end permanent-magnet polishing head is proposed in this paper. The preliminary design focuses on the structural configuration of the machine, which includes the machine body, motion units and accessory equipment, and so on. Structural deformation and fabrication accuracy of the machine are analyzed theoretically, in which the reasonable structure sizes, manufacturing errors and assembly errors of main structural components are given for configuration optimization. Based on the theoretical analysis, a four-axes linkage MRF machine tool is developed. Preliminary experiments of spot polishing are carried out and the results indicate that the proposed MRF process can achieve stable polishing area which meets requirement of deterministic polishing. A typical small-bore complex component is polished on the developed device and fine surface quality is obtained with sphericity of the finished spherical surfaces 1.3 µm and surface roughness Ra less than 0.018 µm.

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Authors and Affiliations

  1. Center for Precision Engineering, Harbin Institute of Technology, Harbin, Heilongjiang, 150001, China

    Henan Liu & Mingjun Chen

  2. China Electronics Technology Group Corporation No.26 Research Institute, Chongqing, 400060, China

    Bo Yu & Zhen Fang

Authors
  1. Henan Liu
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  2. Mingjun Chen
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  3. Bo Yu
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  4. Zhen Fang
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Corresponding author

Correspondence to Mingjun Chen.

Additional information

Recommended by Associate Editor In-Ha Sung

Henan Liu received his M.S. in Mechanical Engineering from Harbin Institute of technology, China, in 2013. He is currently a Ph.D. candidate in Harbin Institute of technology, China. His research interest is magnetorheological finishing for precision optics manufacturing.

Mingjun Chen received his Ph.D. degree in Mechanical Engineering from Harbin Institute of technology, China, in 2001. He is currently a professor and Ph.D. candidate supervisor in Harbin Institute of technology, China. His research interests include precision and ultra-precision machining, micro machining and biomaterial compatibility evaluation.

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Liu, H., Chen, M., Yu, B. et al. Configuration design and accuracy analysis of a novel magnetorheological finishing machine tool for concave surfaces with small radius of curvature. J Mech Sci Technol 30, 3301–3311 (2016). https://doi.org/10.1007/s12206-016-0639-y

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  • DOI: https://doi.org/10.1007/s12206-016-0639-y

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