A new integrated polishing process design for plastic mold steel to mirror-like surface
A new integrated polishing process design for plastic mold steel to mirror-like surface
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DOI：
10.1007/s00170-014-5855-y
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发表时间：
2014-05
期刊：
影响因子：
--
通讯作者：
H. Huang;K. Fuh;Jung-Shu Wu;Y. Tai
中科院分区：
文献类型：
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作者：
H. Huang;K. Fuh;Jung-Shu Wu;Y. Tai
设计了一种新型塑料模具钢抛光工具--柔性抛光头夹具。本文还对这种新型抛光工具的抛光性能进行了研究和评价。这种全新的抛光头柔性夹具的设计，首先是基于Fuh [1]研究中的弱化间隙概念的应用，增加了夹具的微运动自由度。其次，通过有限元法（FEM）进行各种分析和测试。然后，通过频谱图分析了该刀具的加工特性。通过对工件在大、中、小波纹上的抛光性能的分析，评价了抛光效率，并制定了相应的抛光策略。该加工策略过程模块包含切削和抛光一种或多种加工方式的组合以及互补的精密加工方法。最后，我们提出了一套专门针对S-STAR* 的抛光集成工艺技巧。我们还验证了我们的分析与三维轮廓和表面粗糙度测量仪器。结果表明，该方法加工的表面粗糙度可达Ra0.006，形状精度可达Rmax 0.08，PV 0.084 μm。本发明通过光谱分析，可显著提高大波长精度达83.9%，中波长精度达82.5%，小波长精度达80.2%。综上所述，我们的目标是建立一个镜面抛光工具，塑料模具钢。这一建议经过了审慎的验证，应该被认为在理论上和实践上都是成功的。
This paper aims to propose the design of a new polishing tool, a clamp with a flexible polishing head (or CFPH) for polishing plastic mold steel. The investigation/evaluation of this new tool’s performance in polishing is also included in this paper. The design of this brand new flexible clamp with a polishing head is, first of all, based on the application of the concept of weakening gap in the study of Fuh [1] increase in the freedom of micro-movement of the clamp is available. Second, various analyses and tests are done by the finite element method (FEM). Then, through the spectrogram, we analyze this tool’s machining characteristics. Furthermore, by the performance on large waves, medium waves, and small waves of the workpiece, we evaluate the working efficiency and set up a set of polishing strategies. This module of machining strategy process contains the combination of cutting and polishing one kind or multi-kind machining modes and the complementary precision processing methods. Finally, we propose a set of polishing integration process skills specifically on S-STAR*. We also verify our analysis with 3D profiles and the surface roughness measurement instrument. These verified analyses show that roughness and shape precision can be reached to Ra0.006, Rmax0.08, and PV0.084 μm respectively. This new invention, by the spectrum analysis, can significantly improve large wavelength accuracy up to 83.9 %, medium wavelength accuracy 82.5 %, and small wavelength accuracy 80.2 %. To conclude, we aim to set up a mirror-like surface polishing tool for plastic mold steel. This proposal is prudentially verified and should be considered theoretically and practically successful.