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Applied Optics

Applied Optics


  • Editor: Joseph N. Mait
  • Vol. 48, Iss. 13 — May. 1, 2009
  • pp: 2585–2594

Shear stress in magnetorheological finishing for glasses

Chunlin Miao, Shai N. Shafrir, John C. Lambropoulos, Joni Mici, and Stephen D. Jacobs  »View Author Affiliations

Applied Optics, Vol. 48, Issue 13, pp. 2585-2594 (2009)

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We report in situ, simultaneous measurements of both drag and normal forces in magnetorheological finishing (MRF) for what is believed to be the first time, using a spot taking machine (STM) as a test bed to take MRF spots on stationary parts. The measurements are carried out over the entire area where material is being removed, i.e., the projected area of the MRF removal function/spot on the part surface, using a dual force sensor. This approach experimentally addresses the mechanisms governing material removal in MRF for optical glasses in terms of the hydrodynamic pressure and shear stress, applied by the hydrodynamic flow of magnetorheological fluid at the gap between the part surface and the STM wheel. This work demonstrates that the volumetric removal rate shows a positive linear dependence on shear stress. Shear stress exhibits a positive linear dependence on a material figure of merit that depends upon Young’s modulus, fracture toughness, and hardness. A modified Preston’s equation is proposed that better estimates MRF material removal rate for optical glasses by incorporating mechanical properties, shear stress, and velocity.

© 2009 Optical Society of America

OCIS Codes
(160.4670) Materials : Optical materials
(220.4610) Optical design and fabrication : Optical fabrication
(220.5450) Optical design and fabrication : Polishing

ToC Category:
Optical Design and Fabrication

Original Manuscript: February 24, 2009
Revised Manuscript: April 1, 2009
Manuscript Accepted: April 1, 2009
Published: April 29, 2009

Chunlin Miao, Shai N. Shafrir, John C. Lambropoulos, Joni Mici, and Stephen D. Jacobs, "Shear stress in magnetorheological finishing for glasses," Appl. Opt. 48, 2585-2594 (2009)

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  1. S. D. Jacobs, D. Golini, Y. Hsu, B. E. Puchebner, D. Strafford, Wm. I. Kordonski, I. V. Prokhorov, E. Fess, D. Pietrowski, and V. W. Kordonski, “Magnetorheological finishing: A deterministic process for optics manufacturing,” Proc. SPIE 2576, 372-382 ( 1995). [CrossRef]
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  14. Zygo Mark IV xp Interferometer (Zygo Corp., Middlefield, Conn.). This instrument is a 4 in. He-Ne Fizeau interferometer with a wavelength of 632.8 nm. pv for surface flatness and ddp of the spot were measured in micrometers.
  15. Zygo NewView 5000 noncontact white light interferometer, Zygo Corp., Middlefield, Conn. Average microroughness data (pv and rms) were obtained under the following conditions: 20× Mirau objective; 20 μm bipolar scan length; min/mod 5%, unfiltered. This instrument has a lateral resolution of ~1 μm and a vertical resolution of ~0.3 nm.
  16. Single Axis Slim Line Compressive (K9133B21) Force Sensor Measuring System (Kistler Instrument Corp.).
  17. Single Axis Slim Line Shear (K9143B21) Force Sensor Measuring System (Kistler Instrument Corp.).
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  26. M. J. Cumbo, “Chemo-mechanical interactions in optical polishing,” Doctor of Philosophy, Ph.D. dissertation (The Institute of Optics, University of Rochester, 1993).

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