Ultrasonic machining of optical and ceramic materials

Michael Cahill; Michael Bechtold; Rob Bechtold

doi:10.1117/12.2685275

29 November 2023 Ultrasonic machining of optical and ceramic materials

Michael Cahill, Michael Bechtold, Rob Bechtold

Proceedings Volume 12778, Optifab 2023; 1277803 (2023) https://doi.org/10.1117/12.2685275
Event: SPIE Optifab, 2023, Rochester, New York, United States

Abstract

Hard ceramic and optical materials can present substantial challenges in manufacturing due to their tough mechanical properties. The properties that make these materials ideal for a variety of applications also makes them incredibly difficult to machine. Some of the biggest challenges in machining parts are minimizing the amount of sub surface damage (SSD) imparted into the material, slow processing speeds, and increased tool wear. The amount of SSD directly impacts processing time of these parts as additional finer tooling is required for the process or additional polishing time is necessary. Using finer tooling will produce more tool wear and slow down the overall process. To overcome these challenges, OptiPro Systems has developed an ultrasonic assisted grinding technology, OpitSonic, which has been designed for the precision optics and ceramics industry. OptiSonic utilizes a custom tool holder designed to produce oscillations, in the micron amplitude range, in line with the rotating spindle. A software package, IntelliSonic, is integral to the function of the platform. IntelliSonic can automatically characterize tooling during setup to identify and select the ideal resonant peak to operate at. While grinding, IntelliSonic continuously adjusts the output frequency for optimal grinding efficiency while in contact with the part. Using a variety of instruments, tests have proven to show a reduction in SSD while using OptiSonic, leading to decreased processing times and minimized tool wear. This paper will present the challenges associated with these materials and the solutions created to overcome them.

Conference Presentation

(2023) Published by SPIE. Downloading of the abstract is permitted for personal use only.

Citation Download Citation

Michael Cahill, Michael Bechtold, and Rob Bechtold "Ultrasonic machining of optical and ceramic materials", Proc. SPIE 12778, Optifab 2023, 1277803 (29 November 2023); https://doi.org/10.1117/12.2685275

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