OptiSonic: The Latest in Ultrasonic Machining Technology. Ron Colavecchia 11/10/2016

Transcription

1 OptiSonic: The Latest in Ultrasonic Machining Technology Ron Colavecchia 11/10/2016

2 Agenda Why use UltraSonic IntelliSonic software Tool holder developments Test cases Questions and Answers 2

3 3 OptiSonic Grinding Platform

4 Why Ultrasonic? Grinding hard glass and ceramics produces accelerated tool wear. Flat Edge 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. 4 Polishing optics can become more time consuming due to the roughness of the part.

5 OptiSonic Spindle All power transfer occurs within the housing. Labyrinth seal ensures no coolant gets into housing during machining processes. Air Purged housing

6 6 OptiSonic Tool Holder Overview

7 OptiSonic Collet Tool Holder Development 0.012

8 IntelliSonic 8 CNC integration Frequency Sweep Adaptive Frequency Control 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. 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. 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.

9 IntelliSonic

10 Tool Characterization

11 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

12 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

13 Applications Typical 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

14 Core Drilling Comparison 14 Two runs were made, first with ultrasonic off then with it turned on. Both of these tests were performed at the same feed rate. Material: Fused Quartz Data measured using a Kistler 9257B 3-Axis force dynamometer

15 Z Force (N) End Mill Testing mm D46 End Mill - 3,000 mm/min, DOC Time (seconds) Series1 Series2 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. Material: Fused Silica Data measured using a Kistler 9257B 3-Axis force dynometer

16 Long Core Drill 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 ) 16

17 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 0.012

18 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 Ultrasonic on Fine Tool Tool speed (rpm) Depth of Cut (microns) Feed rate (mm/min) Non-ultrasonic Ultrasonic on

19 Set up of experiment Sapphire grinding

20 Toolpath

21 Two toric shaped grinding wheels were used for this test. Both were approximately 65 mm in diameter. The rough tool was an grit and the fine tool was a grit tool. Table 1 below shows the range of process conditions tested during this experiment. Table 1: Processing condition Tool Diamond size (µm) Bond Tool speed (rpm) Depth of cut (mm) Step over (mm) Feed Rate (mm/min) grit grit 181 Bronze Bronze Coolant: UltraCool 5000 Coolant Concentration: 5%

22 Figure 4: Surface roughness after grit tool

23 Tool Life Testing Ultrasonic On Ultrasonic Off Ultrasonic On Ultrasonic Off

24 13 Diameter Zerodur Light weighing At least 3 times faster cycle times with OptiSonic

25 OptiSonic 3X/5X Ultrasonic Machining Technology for Optical Glasses and Ceramics 3 to 5 Axis Capability in 4 different size platforms Fagor CNC Control Simple Windows-based Graphical User Interface (GUI) OptiPro s IntelliSonic Technology 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 25 Ethernet & USB Communications

26 Thank You For more Information: Ron Colavecchia Office: OptiPro Systems, LLC 6368 Dean Parkway Ontario, NY