optisonic: the latest in ultrasonic machining...
TRANSCRIPT
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OptiSonic: The Latest in Ultrasonic Machining Technology
Ron Colavecchia11/10/2016
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• Why use UltraSonic
• IntelliSonic software
• Tool holder developments
• Test cases
• Questions and Answers
Agenda
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OptiSonic Grinding Platform
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• Grinding hard glass and ceramics produces accelerated tool wear.
• Tooling will develop flat edges, tapers, and continually become dull.
• Processing speeds are slow due to unwanted tool load and potential part breakage.
• Grinding parts to the correct size is difficult with harder ceramics.
• Polishing optics can become more time consuming due to the roughness of the part.
Why Ultrasonic?
Flat Edge
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OptiSonic Spindle
• All power transfer occurs within the housing.
• Labyrinth seal ensures no coolant gets into housing during machining processes.
• Air Purged housing
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OptiSonic Tool Holder Overview
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OptiSonic Collet Tool Holder Development
0.012”
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IntelliSonic
Frequency will automatically adjust to the changing conditions inside the part and ensure the tool is kept at the optimal cutting condition. This ensures consistency throughout the part.
Frequency Sweep
Software will automatically sweep through a range of frequencies to determine the ideal frequency to run each tool at. Users can load and characterize new tooling with ease.
CNC integration
Full integration into the Fagor Tool Library. Attributes set during the characterizing of a tool can be easily stored within the tool library. MCodes are able control all necessary Ultrasonic functions.
Adaptive Frequency Control8
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IntelliSonic
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Tool Characterization
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Collet Holder – ER20• Successfully assembled and began use in our lab• Have tested and used tooling shanks that have been as
small as 1mm• Can hold tools with a shank of up to 13mm • Proven to be a good alternative to the shrink holders• Several customers have purchased and are currently
using the ER20 ultrasonic holders
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Larger Ring Tooling• Larger ring tools for contour grinding and large
spherical optics• Currently are using 4” and 6” tooling• Good results exciting a tool that size and mass• Next steps : 8” and 10” ring tools
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ApplicationsTypical Applications:• Light weighting with thin walled
features• Core Drilling• Generating Spheres & Aspheres• Free Form• Rastering• Deep Drilling
Common Materials:• BK7• Zerodur• Fused Quartz• Fused Silica• Pyrex• ALON• Zirconia• PCA• Sapphire• Spinel• Silicon Carbide• Other glass and ceramics
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Core Drilling Comparison
Data measured using a Kistler 9257B 3-Axis force dynamometerMaterial: Fused Quartz
Two runs were made, first with ultrasonic off then with it turned on. Both of these tests were performed at the same feed rate.
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End Mill Testing
-5
5
15
25
35
45
0 20 40 60 80 100 120
Z Fo
rce
(N)
Time (seconds)
3.6mm D46 End Mill - 3,000 mm/min, 0.030 DOC
Series1 Series2
Data measured using a Kistler 9257B 3-Axis force dynometerMaterial: Fused Silica
Two runs were made, first with ultrasonic off then with it turned on. Both of these tests were performed at the same feeds and speeds.
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• Used a Ø4mm OD by 225mm long core drill
• Using the ultrasonic oscillation and a high pressure CTS pump to effectively evacuate the swarf and keep the tool cooled
• Fast feed rates without a pecking routine in BK7
• Less than 10 microns of taper over the length of the core
• Finished part was a Ø2.490mm by 190mm long core – (15 minutes )
Long Core Drill
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Small Holes
• Tools that are Ø150µm (0.006”)• Ø300µm (0.012”) holes into 700µm (0.027”) thick
borosilicate substrate• Around 20 seconds per hole• Spindle only at 3,000 RPM
0.006”
0.012”
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Spinel • Sample material is a piece of fine grain spinel • Goal of testing was to define the optimal grinding
process with and without ultrasonic• A rough (D151) and fine (D46) tool were used• At those parameters examine how ultrasonic can affect
sub surface damage• Using ultrasonic we were able to improve feed rates by
over 3X
Rough Tool Tool speed(rpm)
Depth of Cut(microns)
Feed rate(mm/min)
Non-ultrasonic 8800 100 4000
Ultrasonic on 8800 100 12000
Fine Tool Tool speed(rpm)
Depth of Cut(microns)
Feed rate(mm/min)
Non-ultrasonic 7800 20 2600Ultrasonic on 7800 20 8600
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Set up of experiment – Sapphire grinding
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Toolpath
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Tool Diamond size (µm)
Bond Tool speed(rpm)
Depth of cut (mm)
Step over(mm)
Feed Rate(mm/min)
80-100 grit
181 Bronze 2500 0.3 - 0.5 0.5 2800 – 5000
230-270 grit
64 Bronze 2500 0.05 – 0.25 0.25 3500
Coolant: UltraCool 5000 Coolant Concentration: 5%
Two toric shaped grinding wheels were used for this test. Both were approximately 65 mm in diameter. The rough tool was an 80-100 grit and the fine tool was a 230-270 grit tool. Table 1
below shows the range of process conditions tested during this experiment. Table 1: Processing condition
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Figure 4: Surface roughness after 230-270 grit tool
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Tool Life Testing
Ultrasonic On
Ultrasonic On
Ultrasonic Off
Ultrasonic Off
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13” Diameter Zerodur Light weighing
At least 3 times faster cycle times with OptiSonic
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• Fagor CNC Control
OptiSonic 3X/5XUltrasonic Machining Technology for Optical Glasses and Ceramics• 3 to 5 Axis Capability in 4 different size platforms
• Simple Windows-based Graphical User Interface (GUI)
• Quick Change High Speed Tool Spindles
• Liquid Cooled/Coolant Through Spindle
• Standard 24-tool Carousel Automatic Tool Changer on 3X Model, Different ATC Configurations Available on 5X Model
• Tool Setting Probe/Work Probing System
• Laser Tool Probe Optional
• Ethernet & USB Communications
• OptiPro’s IntelliSonic Technology
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For more Information:
Ron Colavecchia
Office: 585-265-0160
OptiPro Systems, LLC
6368 Dean Parkway
Ontario, NY 14519
585-265-0160
www.optipro.com
Thank You