Micromechanical contributions to material removal and surface finish

Shai N. Shafrir; John C. Lambropoulos; Stephen D. Jacobs

doi:10.1117/12.718406

14 May 2007 Micromechanical contributions to material removal and surface finish

Shai N. Shafrir, John C. Lambropoulos, Stephen D. Jacobs

Proceedings Volume 10316, Optifab 2007: Technical Digest; 1031608 (2007) https://doi.org/10.1117/12.718406
Event: Optifab 2007, 2007, Rochester, New York, United States

Abstract

We study material removal mechanisms of commercially available hard optical materials, with respect to their micromechanical properties, as well as their response to different manufacturing techniques. The materials of interest are heterogeneous materials such as Ni-based (nonmagnetic), Co-based (magnetic), and binderless tungsten carbides, in addition to other hard optical ceramics such as ALON, polycrystalline alumina (PCA), and silicon carbide (SiC). Our experimental work is performed in three stages, emphasizing the contributions of each material’s microstructure to its mechanical response. In the first stage, we identify and characterize material physical properties, such as E-Young's modulus, H_v-Vickers hardness, and K_Ic- fracture toughness (either by microindentation techniques, previously published models, or vendors’ data base). In the second stage, we examine the ability of these materials to be deterministically microground and spotted with magnetorheological finishing (MRF). The evolution of the resulting surface topography is studied using a contact profilometer, white light interferometry, scanning electron microscopy, and atomic force microscopy. In the third stage, we demonstrate that subsurface damage (SSD) depth can be estimated by correlating surface microroughness measurements, specifically, the peakto- valley (p-v) microroughness, to the amount of material removed by an MRF spot.

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Shai N. Shafrir, John C. Lambropoulos, and Stephen D. Jacobs "Micromechanical contributions to material removal and surface finish", Proc. SPIE 10316, Optifab 2007: Technical Digest, 1031608 (14 May 2007); https://doi.org/10.1117/12.718406

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KEYWORDS

Magnetorheological finishing

Surface finishing

Optics manufacturing

Surface roughness

Tungsten

Magnetism

Scanning electron microscopy

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