|
|
Review on the progress of ultra-precision machining technologies |
Julong YUAN(), Binghai LYU, Wei HANG, Qianfa DENG |
Ultra-precision Machining Center, Zhejiang University of Technology, Hangzhou 310014, China; Key Laboratory of E&M, Zhejiang University of Technology (Ministry of Education and Zhejiang Province), Hangzhou 310014, China |
|
|
Abstract Ultra-precision machining technologies are the essential methods, to obtain the highest form accuracy and surface quality. As more research findings are published, such technologies now involve complicated systems engineering and been widely used in the production of components in various aerospace, national defense, optics, mechanics, electronics, and other high-tech applications. The conception, applications and history of ultra-precision machining are introduced in this article, and the developments of ultra-precision machining technologies, especially ultra-precision grinding, ultra-precision cutting and polishing are also reviewed. The current state and problems of this field in China are analyzed. Finally, the development trends of this field and the coping strategies employed in China to keep up with the trends are discussed.
|
Keywords
ultra-precision grinding
ultra-precision cutting
ultra-precision polishing
research status in China
development tendency
|
Corresponding Author(s):
Julong YUAN
|
Just Accepted Date: 16 May 2017
Online First Date: 07 June 2017
Issue Date: 19 June 2017
|
|
1 |
Yuan Z, Wang X. The Technology of Precision Machining and Ultra-Precision Machining. 3rd ed. Beijing: China Machine Press, 2016 (in Chinese)
|
2 |
Editing Committee of Microfabrication Technology. Microfabrication Technology. Beijing: Science Press, 1983 (in Chinese)
|
3 |
Komanduri R, Lucca D A, Tani Y. Technological advances in fine abrasive processes. CIRP Annals—Manufacturing Technology, 1997, 46(2): 545–596
https://doi.org/10.1016/S0007-8506(07)60880-4
|
4 |
Ikawa N, Shimada S. Accuracy problems in ultra-precision metal cutting. Journal of the Japan Society of Precision Engineering, 1986, 52(12): 2000–2004 (in Japanese)
https://doi.org/10.2493/jjspe.52.2000
|
5 |
Shimada S, Ikawa N, Tanaka H, et al. Feasibility study on ultimate accuracy in micro-cutting using molecular dynamics simulations. CIRP Annals—Manufacturing Technology, 1993, 42(1): 91–94
https://doi.org/10.1016/S0007-8506(07)62399-3
|
6 |
Byrne G, Dornfeld D, Denkena B. Advancing cutting technology. CIRP Annals—Manufacturing Technology, 2003, 52(2): 483–507
https://doi.org/10.1016/S0007-8506(07)60200-5
|
7 |
Edward P, David S, Scott C. MOLDED OPTICS: Molded glass aspheric optics hit the target for precision and cost. Laser Focus World, 2007, 43(12): 71–74
|
8 |
Kim H S, Lee K I, Lee K M, et al. Fabrication of free-form surfaces using a long-stroke fast tool servo and corrective figuring with on-machine measurement. International Journal of Machine Tools and Manufacture, 2009, 49(12–13): 991–997
https://doi.org/10.1016/j.ijmachtools.2009.06.011
|
9 |
Rakuff S, Cuttino J F. Design and testing of a long-range, precision fast tool servo system for diamond turning. Precision Engineering, 2009, 33(1): 18–25
https://doi.org/10.1016/j.precisioneng.2008.03.001
|
10 |
Tohme Y E, Lowe J A. Machining of freeform optical surfaces by slow slide servo method. In: Proceedings of the American Society for Precision Engineering Annual Meeting. 2003
|
11 |
Wei H. Ultra-precision machining & manufacturing of optical devices [EB/OL]. 2011. Retrieved from (in Chinese)
|
12 |
Weck M, Klocke F. Manufacturing and applications of non-rotationally symmetric optics. SPIE Proceedings, Optical Fabrication and Testing, 1999, 3739: 94–107
https://doi.org/10.1117/12.360133
|
13 |
Gao W. Precision nano-fabrication and evaluation of a large area sinusoidal grid surface for a surface encoder. Precision Engineering, 2003, 27(3): 289–298
https://doi.org/10.1016/S0141-6359(03)00028-X
|
14 |
Ohmori H, Nakagawa T. Mirror surface grinding of silicon wafers with electrolytic in-process dressing. CIRP Annals—Manufacturing Technology, 1990, 39(1): 329–332
https://doi.org/10.1016/S0007-8506(07)61065-8
|
15 |
Matsumura T, Hiramatsu T, Shirakashi T, et al. A study on cutting force in the milling process of glass. Journal of Manufacturing Processes, 2005, 7(2): 102–108
https://doi.org/10.1016/S1526-6125(05)70087-6
|
16 |
Matsumura T, Ono T. Cutting process of glass with inclined ball end mill. Journal of Materials Processing Technology, 2008, 200(1–3): 356–363
https://doi.org/10.1016/j.jmatprotec.2007.08.067
|
17 |
Ono T, Matsumura T. Influence of tool inclination on brittle fracture in glass cutting with ball end mills. Journal of Materials Processing Technology, 2008, 202(1–3): 61–69
https://doi.org/10.1016/j.jmatprotec.2007.08.068
|
18 |
Foy K, Wei Z, Matsumura T, et al.Effect of tilt angle on cutting regime transition in glass micromilling. International Journal of Machine Tools and Manufacture, 2009, 49(3–4): 315–324
https://doi.org/10.1016/j.ijmachtools.2008.10.007
|
19 |
Suzuki H, Moriwaki T, Yamamoto Y, et al. Precision cutting of aspherical ceramic molds with micro PCD milling tool. CIRP Annals—Manufacturing Technology, 2007, 56(1): 131–134
https://doi.org/10.1016/j.cirp.2007.05.033
|
20 |
Scheiding S, Eberhardt R, Gebhardt A, et al.Micro lens array milling on large wafers. Optik & Photonik, 2009, 4(4): 41–45
|
21 |
Malkin S, Guo C. Grinding Technology. 2nd ed. South Norwalk: Industrial Press Inc., 2007
|
22 |
Su H, Xu H, Fu Y. Reviewthe current questions and strategies about multilayer sintering super abrasive tools and conceive the development of future tools. Chinese Journal of Mechanical Engineering, 2005, 42(3): 12–17
|
23 |
Webster J, Tricard M. Innovations in abrasive products for precision grinding. CIRP Annals—Manufacturing Technology, 2004, 53(2): 597–617
https://doi.org/10.1016/S0007-8506(07)60031-6
|
24 |
Tannaka T. New development of metal bonded diamond wheel with pore by the growth of bonding bridge. International Journal of the Japan Society for Precision Engineering, 1992, 26(1): 27–32
|
25 |
Chattopadhya A K, Chollet L, Hintermann H E. Induction brazing of diamond with diamond Ni-Cr hadfacing alloy under argon atmosphere. Surface and Coatings Technology, 1991, 45(1–3): 293–298
https://doi.org/10.1016/0257-8972(91)90235-O
|
26 |
Ikeno J, Tani Y, Sato H. Nanometer grinding using ultrafine abrasive pellets—Manufacture of pellets applying electrophoretic deposition. CIRP Annals—Manufacturing Technology, 1990, 39(1): 341–344
https://doi.org/10.1016/S0007-8506(07)61068-3
|
27 |
Ohmori H, Nakagawa T. Mirror surface grinding of silicon wafers with electrolytic in-process dressing. CIRP Annals—Manufacturing Technology, 1990, 39(1): 329–332
https://doi.org/10.1016/S0007-8506(07)61065-8
|
28 |
Kramer D, Rehsteiner F, Schumacher B. ECD (electrochemical in-process controlled dressing), a new method for grinding of modern high-performance cutting materials to highest quality. CIRP Annals—Manufacturing Technology, 1999, 48(1): 265–268
https://doi.org/10.1016/S0007-8506(07)63180-1
|
29 |
Wang Y, Zhou X, Hu D. An experimental investigation of dry-electrical discharge assisted truing and dressing of metal bonded diamond wheel. International Journal of Machine Tools and Manufacture, 2006, 46(3–4): 333–342
https://doi.org/10.1016/j.ijmachtools.2005.05.022
|
30 |
Suzuki K, Uematsu T, Yanase T, et al. Development of a simplified electrochemical dressing method with twin electrodes. CIRP Annals—Manufacturing Technology, 1991, 40(1): 363–366
https://doi.org/10.1016/S0007-8506(07)62007-1
|
31 |
Bhattacharyya B, Doloi B N, Sorkhel S K. Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic materials. Journal of Materials Processing Technology, 1999, 95(1–3): 145–154
https://doi.org/10.1016/S0924-0136(99)00318-0
|
32 |
Zhang C, Shin Y C. A novel laser-assisted truing and dressing technique for vitrified CBN wheels. International Journal of Machine Tools and Manufacture, 2002, 42(7): 825–835
https://doi.org/10.1016/S0890-6955(02)00014-7
|
33 |
Hirao M, Izawa M. Water-jet in-process dressing (1st report): Dressing property and jet pressure. Journal of the Japan Society of Precision Engineering, 1998, 64(9): 1335–1339 (in Japanese)
|
34 |
Ikuse Y, Nonokawa T, Kawabatan N, et al. Development of new ultrasonic dressing equipment. Journal of the Japan Society of Precision Engineering, 1995, 61(7): 986–990 (in Japanese)
|
35 |
Ohmori H, Nakagawa T. Analysis of mirror surface generation of hard and brittle materials by ELID (electrolytic in-process dressing) grinding with superfine grain metallic bond wheels. CIRP Annals —Manufacturing Technology, 1995, 44(1): 287–290
https://doi.org/10.1016/S0007-8506(07)62327-0
|
36 |
Lambropoulos J C, Gillman B E, Zhou Y, et al. Glass-ceramics: Deterministic microgrinding, lapping and polishing. SPIE Proceedings, Optical Manufacturing and Testing II, 1997, 3134: 178–189
https://doi.org/10.1117/12.279119
|
37 |
Jeff R, Ed F, Dennis V G,et al. Contour grinding results on the NanotechTM 150AG. Convergence, 1999, 7(3): 1–8
|
38 |
Zhou L, Eda H, Shimizu J, et al. Defect-free fabrication for single crystal silicon substrate by chemo-mechanical grinding. CIRP Annals—Manufacturing Technology, 2006, 55(1): 313–316
https://doi.org/10.1016/S0007-8506(07)60424-7
|
39 |
Hang W, Zhou L, Zhang K, et al. Study on grinding of LiTaO3 wafer using effective cooling and electrolyte solution. Precision Engineering, 2016, 44: 62–69
https://doi.org/10.1016/j.precisioneng.2015.10.001
|
40 |
Kasai T, Doy T. Grinding, lapping and polishing technologies under nanometer scale working conditions. Journal of the Japan Society of Precision Engineering, 1993, 59(4): 559–562 (in Japanese)
https://doi.org/10.2493/jjspe.59.559
|
41 |
Wang J, Wang T, Pan G, et al. Effect of photocatalytic oxidation technology on GaN CMP. Applied Surface Science, 2016, 361: 18–24
https://doi.org/10.1016/j.apsusc.2015.11.062
|
42 |
Yuan J. Ultraprecision Machining of Functional Ceramics. Harbin: Press of Harbin Institute of Technology, 2000 (in Chinese)
|
43 |
Mori Y, Ikawa N, Okuda T, et al. Numerically controlled elastic emission machine. Journal of the Japan Society of Precision Engineering, 1980, 46(12): 1537–1544
|
44 |
Uzawa S. Canon’s development status of EUVL technologies. In: Proceedings of the 4th EUVL Symposium. 2005
|
45 |
Watanabe J, Suzuki J, Kobayashi A. High precision polishing of semiconductor materials using hydrodynamic principle. CIRP Annals—Manufacturing Technology, 1981, 30(1): 91–95
https://doi.org/10.1016/S0007-8506(07)60902-0
|
46 |
Namba Y, Tsuwa H. Ultra-fine finishing of sapphire single crystal. CIRP Annals—Manufacturing Technology, 1977, 26(1): 325–329
|
47 |
Yasunaga N, Obara A, Tarumi N. Study of mechanochemical effect on wear and its application to surface finishing. Journal of the Japan Society for Precision Engineering, 1977, 776: 50–134
|
48 |
Steigerwald J M, Murarka S P, Gutmann R J. Chemical Mechanical Planarization of Microelectronic Materials. New York: John Wiley & Sons Inc., 1996
|
49 |
Pirayesh H, Cadien K. Chemical mechanical polishing in the dry lubrication regime: Application to conductive polysilicon. Journal of Materials Processing Technology, 2015, 220: 257–263
https://doi.org/10.1016/j.jmatprotec.2015.01.027
|
50 |
Fox M, Agrawal K, Shinmura T, et al. Magnetic abrasive finishing of rollers. CIRP Annals—Manufacturing Technology, 1994, 43(1): 181–184
https://doi.org/10.1016/S0007-8506(07)62191-X
|
51 |
Tani Y, Kawata K, Nakayama K. Development of high-efficient fine finishing process using magnetic fluid. CIRP Annals—Manufacturing Technology, 1984, 33(1): 217–220
https://doi.org/10.1016/S0007-8506(07)61412-7
|
52 |
Suzuki K, Ide A, Uematsu T, et al. Electrophoresis-polishing with a partial electrode tool. In: Proceedings of the International Symposium on Advances in Abrasive Technology. 1997, 48–52
https://doi.org/10.1142/9789814317405_0007
|
53 |
Martin H M, Allen R G, Burge J H F,et al. Fabrication of mirrors for the Magellan telescopes and large binocular telescope. SPIE Proceedings, Large Ground-based Telescopes, 2003, 4837: 1–10
https://doi.org/10.1117/12.458606
|
54 |
Kim D W, Burge J H. Rigid conformal polishing tool using non-linear visco-elastic effect. Optics Express, 2010, 18(3): 2242–2257
https://doi.org/10.1364/OE.18.002242
|
55 |
Walker D D, Brooks D, King A, et al. The “precessions” tooling for polishing and figuring flat, spherical and aspheric surfaces. Optical Express, 2003, 11(8): 958–964
https://doi.org/10.1364/OE.11.000958
|
56 |
Walker D D, Beaucamp A T H, Binghama R G, et al. Precessions aspheric polishing: New results from the development program. SPIE Proceedings, Optical Manufacturing and Testing V, 2003, 5180: 15–28
https://doi.org/10.1117/12.507462
|
57 |
Jacobs S, Arrasmith S, Kozhinova I. An overview of magnetorheological finishing (MRF) for precision optics manufacturing. Ceramic Transactions, 1999, 102: 185–199
|
58 |
Booij S M. Fluid jet polishing—Possibilities and limitations of a new fabrication technique. Dissertation for the Doctoral Degree. Delft: Delft University of Technology, 2003
|
59 |
Beaucamp A, Freeman R, Morton R, et al. Removal of diamond-turning signatures on x-ray mandrels and metal optics by fluid-jet polishing. SPIE Proceedings, Advanced Optical and Mechanical Technologies in Telescopes and Instrumentation, 2008, 7018: 701835
https://doi.org/10.1117/12.787960
|
60 |
Shorey A, Kordonski W, Tricard M. Deterministic precision finishing of domes and conformal optics. SPIE Proceedings, Window and Dome Technologies and Materials IX, 2005, 5786: 310–318
https://doi.org/10.1117/12.607456
|
61 |
Tricard M, Kordonski W I, Shorey A B,et al. Magnetorheological jet finishing of conformal, freeform and steep concave optics. CIRP Annals—Manufacturing Technology, 2006, 55(1): 309–312
https://doi.org/10.1016/S0007-8506(07)60423-5
|
62 |
Cheng Y, Fang F, Zhang X. Ultra-precision turning of aspheric mirrors using error-decreasing amendment method. Optical Technique, 2010, 36(1): 51–55 (in Chinese)
|
63 |
Fang F, Liu X, Lee L. Micro-machining of optical glasses—A review of diamond-cutting glasses. Sadhana, 2003, 28(5): 945–955
|
64 |
Guan C, Tie G, Yin Z. Fabrication of array lens optical component by using of slow tool servo diamond turning. Journal of National University of Defense Technology, 2009, 31(4): 31–47 (in Chinese)
|
65 |
Li L, Yi A Y, Huang C, et al. Fabrication of diffractive optics by use of slow tool servo diamond turning process. Optical Engineering, 2006, 45(11): 113401
https://doi.org/10.1117/1.2387142
|
66 |
Lee W B, Cheung C F, To S, et al. Integrated manufacturing technology for design, machining and measurement of freeform optics. Journal of Mechanical Engineering, 2010, 46(11): 137–148
https://doi.org/10.3901/JME.2010.11.137
|
67 |
Zhou P, Xu S, Wang Z, et al. A load identification method for the grinding damage induced stress (GDIS) distribution in silicon wafers. International Journal of Machine Tools and Manufacture, 2016, 107(8): 1–7
https://doi.org/10.1016/j.ijmachtools.2016.04.010
|
68 |
Huang Y, Huang Z. Modern Abrasive Belt Grinding Technology and Engineering Application. Chongqing: Chongqing University Press, 2009 (in Chinese)
|
69 |
Zhang F. Fabrication and testing of precise off-axis convex aspheric mirror. Optics and Precision Engineering, 2010, 18(12): 2557–2563
|
70 |
Dai Y, Shang W, Zhou X. Effect of the material of a small tool to removal function in computer control optical polishing. Journal of National University of Defense Technology, 2006, 28(2): 97–101 (in Chinese)
|
71 |
Shun X, Zhang F, Dong S.Research on remove model and algorithm of resident time for magnetorheological finishing. New Technology & New Process, 2006, (2): 73–75 (in Chinese)
|
72 |
Liao W, Dai Y, Zhou L, et al. Optical surface roughness in ion beam process. Journal of Applied Optics, 2010, 31(6): 1041–1045 (in Chinese)
|
73 |
Guo P, Fang H, Yu J. Research on material removal mechanism of fluid jet polishing. Laser Journal, 2008, 29(1): 25–27 (in Chinese)
|
74 |
Zhang X, Dai Y, Li S. Study on magnetorheological jet polishing technology. Machinery Design & Manufacture, 2007, (12): 114–116 (in Chinese)
|
75 |
Zhang J, Wang B, Dong S. Application of atmospheric pressure plasma polishing method in machining of silicon ultra smooth surface. Optics and Precision Engineering, 2007, 15(11): 1749–1755 (in Chinese)
|
76 |
Zhang Y, Feng Z, Wang Y. Study of magnetorheological brush finishing (MRBF) for concave surface of conformal optics. In: Proceedings of the 8th China-Japan International Conference on Ultra-Precision Machining. Hangzhou, 2011
|
77 |
Hong T. Research on the machining mechanics of EMR effect-based tiny-grinding wheel. Dissertation for the Doctoral Degree. Guang-zhou: Guangdong University of Technology, 2008
|
78 |
Li M, Lyu B H, Yuan J, et al. Shear-thickening polishing method. International Journal of Machine Tools and Manufacture, 2015, 94: 88–99
https://doi.org/10.1016/j.ijmachtools.2015.04.010
|
79 |
Zhao T, Deng Q, Yuan J, et al. An experimental investigation of flat polishing with dielectrophoretic (DEP) effect of slurry. International Journal of Advanced Manufacturing Technology, 2016, 84(5–8): 1737–1746
|
80 |
Yuan J, Wang Z, Hong T, et al. A semi-fixed abrasive machining technique. Journal of Micromechanics and Microengineering, 2009, 19(5): 054006
https://doi.org/10.1088/0960-1317/19/5/054006
|
81 |
Qi J, Luo J, Wang K, et al. Mechanical and tribological properties of diamond-like carbon films deposited by electron cyclotron resonance microwave plasma chemical vapor deposition. Tribology Letters, 2003, 14(2): 105–109
https://doi.org/10.1023/A:1021704320444
|
82 |
Su J, Guo D, Kang R, et al. Modeling and analyzing on nonuniformity of material removal in chemical mechanical polishing of silicon wafer. Materials Science Forum, 2004, 471–472: 26–31
|
83 |
Yuan J, Chen L, Zhao P, et al. Study on sphere shaping mechanism of ceramic ball for lapping process. Key Engineering Materials, 2004, 259–260: 195–200
https://doi.org/10.4028/www.scientific.net/KEM.259-260.195
|
84 |
Zhou F, Yuan J, Lyu B H, et al. Kinematics and trajectory in processing precision balls with eccentric plate and variable-radius V-groove. International Journal of Advanced Manufacturing Technology, 2016, 84(9–12): 2167–2178
https://doi.org/10.1007/s00170-015-7855-y
|
|
Viewed |
|
|
|
Full text
|
|
|
|
|
Abstract
|
|
|
|
|
Cited |
|
|
|
|
|
Shared |
|
|
|
|
|
Discussed |
|
|
|
|