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Understanding the tool influence function during sub-aperture belt-on-wheel glass polishing.

T Suratwala, J Ross, R Steele

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    The tool influence function in belt-on-wheel polishing was studied. A modified Preston model accurately predicts removal rates, offering an economical initial polish for optics.

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    Area of Science:

    • Materials Science
    • Manufacturing Engineering
    • Optical Engineering

    Background:

    • Sub-aperture polishing is crucial for high-precision optics.
    • Understanding the tool influence function (TIF) is key to process optimization.
    • Fused silica glass is a common material for optical components.

    Purpose of the Study:

    • To evaluate the tool influence function (TIF) in sub-aperture belt-on-wheel polishing.
    • To investigate the impact of various process conditions on TIF and removal rates.
    • To validate a modified Preston model for predicting material removal.

    Main Methods:

    • Experimental evaluation of TIF under varied process conditions (belt wear, dwell time, displacement, velocity, wheel modulus/diameter).
    • Utilized cerium oxide (CeO2) polishing media on fused silica workpieces.
    • Applied a modified Preston model with adjusted wheel modulus scaling (Ew^0.5).

    Main Results:

    • TIF spots were characterized as circular/elliptical with flat bottoms.
    • Volumetric removal rate showed significant dependence on belt wear, stabilizing after ~15 minutes.
    • The modified Preston model successfully predicted volumetric removal rates across tested conditions.

    Conclusions:

    • The study provides insights into TIF behavior during belt-on-wheel polishing.
    • A high volumetric removal rate (30-60 mm³/h) was achieved with a CeO2-in-resin belt.
    • This method offers a rapid and economical initial polishing solution for aspheric and freeform optics.