Netaji Subhash Institute of Technology

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Contents
1. Introduction 2. Magneto Rheological Materials 3. Working Principle 4. Need for develop ent of !echnolog" 5. $o e co petent technologies &. MR' in achine cell 3 4 5 # % 1( 11 11 achine 11 12

#. )dvantages %. )pplications *. +ase, Ne- MR' 1(. References

Introduction
Manufacturing of aspheric lenses precisel" has al-a"s re ains a hard .o/ for the optician. !echnologies availa/le to hi onl" inspire hi to take .o/ of producing spherical co ponents. ) ne- technolog" is introduced /" 012 technologies na ed Magneto Rheological 'inishing. Magneto rheological finishing 3MR'4 is aking inroads into the arketplace /ecause it is a deter inistic polishing process that easil" fits into the nor al optical production environ ent. Its ke" attri/ute is that it e plo"s agneto rheological fluid as a polishing tool. !he MR fluid acts as a co pliant polishing lap5 -hose shape and stiffness can /e agneticall" anipulated and controlled in real ti e. !he e6tre e sta/ilit" of the polishing tool5 coupled -ith nearl" infinite co pliance to an aspheric -ork piece5 akes the MR' technolog" a significant advance in deter inistic polishing of all optics7spheres5 flats5 and aspherics. MR' achines have /een deplo"ed at ore than 5( optical fa/rication facilities all over the -orld5 -hich akes this a ainstrea and accessi/le technolog". 819

Magneto Rheological Materials

Magneto rheological 3MR4 fluids are a class of controlla/le fluid -hose rheological properties a" /e rapidl" varied /" the application of a agnetic field. $uch controlla/le fluids -hose rheolog" a" /e varied /" the application of an e6ternal input have long /een seen as offering the possi/ilit" of si ple5 :uiet5 rapid response interfaces /et-een electronic controls and echanical s"ste s. Magneto rheological 3MR4 fluids5 -hich are dense suspensions of icro eter;si<ed agneti<a/le particles in li:uids5 can /e rapidl" and reversi/l" solidified /" the application of a agnetic field. While these field;induced rheological changes are central to the operation of MR;fluid; /ased controlla/le devices !he application of a constant agnetic field to e ulsion induces a agnetic dipole o ent in each of the e ulsion droplets3fig 14. 2ue to the induced dipole;dipole interaction the droplets align the selves into chains. 829

'ig 1, MR fluid pheno ena under

agnetic field

Working Principle
) -ork piece is installed at a fi6ed distance fro a oving spherical -heel. )/out 1 liter of agneto rheological fluid is loaded into the closed;loop fluid deliver" s"ste . 'luid properties such as te perature and viscosit" are continuall" onitored and controlled. !he fluid is dra-n out of the conditioner and e6truded onto a rotating spherical -heel in a thin ri//on that -ill contact the optical surface. !he ri//on is then re oved via suction and fed /ack into the conditioner. )n electro agnet located /elo- the polishing -heel generates a gradient agnetic field in the gap /et-een the -heel and the -ork piece. It has speciall" designed pole pieces that e6tend up to the underside of the ape6 of the -heel ri . !hese pole pieces e6ert a strong local agnetic field gradient over the upper side of the -heel. 839 When the MR fluid is delivered to the -heel5 it is pulled against the -heel surface /" the agnetic field gradient. !he fluid ac:uires the -heel velocit". !he MR fluid passes through the agnetic field5 it stiffens in illiseconds5 and then returns to its original fluid state as it leaves the field5 again in illiseconds. !his precisel" controlled <one of agneti<ed fluid /eco es the polishing tool. When an optical surface is placed into the fluid in this <one5 the stiffened fluid la"er is =s:uee<ed= fro its original thickness of a/out 2 5 to a/out l . !he =s:uee<ing= action results in significant shear stress and a polishing pressure over that section of the optical surface. )t the sa e instant5 the MR fluid confor s to the local curvature of the part /eing polished. !he re oval rate of this tool correlates ver" -ell -ith the viscosit" of the fluid5 -hich is controlled in situ to >1?.
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) sophisticated co puter progra deter ines a schedule for var"ing the position of the rotating -ork piece through the polishing <one.

Fig ! Process description

Need for de"elop#ent of Technology

MR' technolog" has /een developed on the need of optical industr". @lass is one of the fe- aterials that can hold ver" s all tolerances. )spheric lenses can /e an effective alternative to ulti;ele ent co ponent s"ste s /" reducing -eight5 overall si<e and cost in an" applications 849. Manufacturing aspheric optical co ponent is co pletel" different fro spherical or flat optics5 and ever" aspect of the specification 3lo-;5 id;5 and high;fre:uenc"4 re:uires hard -ork. 'urther5 there have /een ver" fe- anufacturing tools and ethodologies5 as -ell as etrolog" tools that can achieve such precise specifications. Most of the ethodologies e plo"ed earlier are useful for onl" spherical or flat optics. $o e of the technologies used are,

Fig $! %epicts an aspheric departure fro# best fit cur"e&'(

So#e Co#petent Technologies

Technologies Ancient technology used /" Ro ans for shaping ge stones. ) t"pical polishing tool is appro6i atel" the sa e si<e as the lens surface and is the perfect ate for the lens. +ushioned /" slurr" of -ater and soft polishing a/rasives5 the t-o surfaces are rotated and oscillated against each other to "ield a ver" s ooth optical surface.

%ra)backs

More skill re:uire ent5 can onl" utili<ed for spherical and flat optics. )s the lap /egins to -ear5 the lap and the -ork piece no longer have the proper ating surfaces that destro"s the aspheric shape.

Peripheral grinding is a high speed;grinding -heel is oved against rotating optical surface. It is utili<ed for aspheric also.

'ig 4,

'or of surface sensitive to positional accurac" of achine5 grinding -heel surface5 vi/rations in s"ste . Needs post ;polishing processes5 -hich degrades for .

Peripheral @rinding

Precision Grinding have used Apti al grinding precision achine tools -ith high; depends on a variet" speed spindles and fine grinding of ever;changing -heels. !he goal is to achieve final varia/les5 ost for accurac" on a generating nota/l" the condition achine -hile introducing ini al of the grinding surface and su/surface for da age. -heel. Nearl" an" polishing process that follo-s generation -ill degrade the for even as it i proves finish5 so ini i<ing polishing results in less figure degradation. !his strateg" is sound /ut difficult to i ple ent. *+, -- platfor# fro# Schneider
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.ptic #achines 3$teffen/erg5 @er an"4 utili<e a t-o;spindle achine -ith an auto atic tool changer to cluster a nu /er of grinding -heels and s oothing pads. It has a grinding techni:ue that co /ines rough spherical generating -ith rough and fine contouring5 follo-ed /" pad s oothing and final centering. ) final integrated centering step is essential for an aspheric5 /ecause it auto aticall" places the optical a6is at the echanical center of the aspheric surface.849

;;2A;;

)ll of these approaches suffer fro the sa e pro/le , the" are not deter#inistic /ecause the polishing tools change uncontrolla/l" -ith ti e. *spheric fabrication re/uires sub0aperture approaches because of the #isfit bet)een tool and )ork piece1 Ather innovative5 deter inistic su/; aperture aterial;re oval processes have /een developed over the "ears. Ion /ea figuring5 in particular5 can /e successful in certain niche applications5 /ut it has not /een universall" deplo"ed. 849

MRF in Machine cell

) t"pical achine cell containing a ne-l" installed cell is depicted in figure. It a" contain old generating B polishing achines. !hese achines are utili<ed for aking si ple

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spherical co ponents. )n MR' interacts -ith Caser interfero eter achines.

'ig 5, MR' in

Dc cell 859

*d"antages
EPolishing !ool never dulls or changes. EPolishing !ool is a co pliant fluid5 hence adapts to co ple6 shapes. EFigher re oval rates. ERapid and relia/le control over pad shape using agnetic fields5 thus eli inating the need for dedicated tooling E@ives deter inistic polishing, reduces skill re:uire ents5 product :ualit" and repeata/ilit"5 productivit"5 "ield5 and cost effectiveness.

*pplications
EFigh aspect ratio optics and su/strates 3thin fil filter su/strates for teleco 5 hard disks5 silicon -afers4

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EAptical glasses5 single cr"stals 3calciu flouride5 silicon4 and cera ics 3$i+5 W+4 EPrecision polishing for s:uares5 rectangles5 pris s5 and c"linders5 as -ell as flats5 spheres5 and aspheric

Case! Ne)ly %e"eloped #achine of MRF #achine

Characteristics: Model 022 G 4(( 6. Work piece range fro 1( to 4(( in dia eter Mini u radius of concave lenses 35;4( Figh precision aspherics5 spheres and flats $urface roughness less than 1(H r s and no su/surface da age 819

References
1. Ihttp,DD---.:ed rf.co J 2. +onference on IIntelligent Materials and $"ste s $ art 'luids 3II4J March 215 Roo 43((F5 +onv. +enter5 $ession $22.(1;.(3. 3.Jhttp,DD---.opticse6cellence.orgJ 4.Jhttp,DD---.oe ag<ine.co J 5. Ihttp,DD---.hkpc.orgDopticsDJ

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