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Fig 423: The basic ELID system showing the crucial requirement of a cast iron bond for a grinding wheel to
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function grinding fluid as an electrolyte [41]
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The power supply for ELID is used to control the dressing current, voltage and pulse width of the dressing process The metal-bonded wheel is made into the positive pole through the application of a brush smoothly contacting the wheel shaft, and the electrode is made into the negative pole In the small clearance between the positive and negative poles (01-03 mm), electrolysis occurs through the supply of the grinding fluid and an electrical current
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Fig 424: A schematic illustration of the ELID grinding principle [40]
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It is to be noted that cast iron is a recommended bond for use in an ELID grinding wheel An important feature to note on ELID grinding is that an oxide hydroxide (insulation) layer is formed on the surface of the ELID wheel by electrolysis The oxide hydroxide layer has a lower electrolytic conductivity, and it stops undergoing excessive electrolysis on the grinding wheels Figure 424 describes the mechanism of the ELID grinding of a metal-bonded diamond wheel After truing (a), the grains and the bonding material of the wheel surface are flattened The trued wheel needs to be electrically pre-dressed so that the grains on the wheel surface protrude When pre-dressing is started (b), the bonding material flows out from the grinding wheel, and an insulating layer composed of the oxidized bonding material is formed on the wheel surface (c) This insulating layer reduces the electrical conductivity of the wheel surface and prevents an excessive flow of the bonding material from the wheel As grinding begins, (d), the diamond grains wear out, and the layer also becomes worn out (e) As a result, the electrical conductivity of the wheel surface increases and the electrolytic dressing restarts with the flow of the bonding material from the grinding wheel This cycle is repeated during the grinding process to achieve a stable grinding [40] [42] [43] ELID has now become the most efficient method for dressing metal-bonded grinding wheels continuously, which eliminates the wheel loading and glazing problems encountered during the grinding process [40] It has been reported that surface roughness (Ra) achieved with the ELID process can be as low as 033 nm on BK7 glass and silicon when using an ultra-fine #3000000 grit metallic bond wheel [40] There are numerous applications of ELID, which have been successfully used for processes such as surface grinding, cylindrical grinding, internal grinding and centreless grinding Some other applications are in abrasive cut-off of ceramics [44], mirror surface grinding of silicon wafers [40], small-hole machining of ceramic materials [45], sawing of steel, polymer, sapphire and glass [46], precision machining of CVC-SiC reflection mirrors and mirror internal cylindrical grinding on steels and alumina components [47]
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443 Various Methods for Generating an Aspheric Surface
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In recent years, there has been a dramatic advancement in the field of optics, astronomy, and infrared applications This led to an ever-increasing demand for simple and complex aspheric surfaces which produce a better image quality when compared to that produced by spherical lenses An aspheric surface is generally defined as a surface with a basic conical section form To this basic conical section, a symmetrical deviation can also be superimposed and is given by a symmetrical polynomial expression as follows [48]: Z=
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shape X R + R ( + k ) X + AX + A X +
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X is the horizontal distance from the aspheric axis, Z is the corresponding vertical distance or the vertical sag, Shape = 1 for convex = +1 for concave
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R = radius of curvature, and k = conic constant as given below: k < 1 Hyperboloid k = 1 Paraboloid 1< k < 0 Ellipsoid k=0 Sphere k>0 Oblate ellipsoid The remaining terms in the preceding equation are the symmetrical deviations from the basic conical form The vertical sag of a spherical surface and an aspheric surface with their basic equations and symmetrical deviation is shown Fig 425: How sag can differentiate between in Figure 425 aspheric and spherical surfaces [49] The manufacture of such aspherics has always been a challenge, especially in infrared window materials and metals Therefore, manufacturers and researchers all over have put in a lot of effort to systematically apply measurement science to the design, manufacture, and the fabrication of highly precise devices to achieve low tolerances, better surface finish and low subsurface damage at a reduced cost The principal use of aspheric lens designs is the reduction or elimination of optical aberrations produced when looking through an ophthalmic lens obliquely We will begin our discussion of aspherics by exploring some of these optical aberrations and their effects For ophthalmic lenses, a lens aberration occurs when rays of light fail to come to a point focus at the ideal image position of the eye (called the far point) as it rotates about its centre Fig 426: Rays of light from an object point strike the lens Astigmatic focusing error, which is obliquely and are focused into two separate focal illustrated in Figure 427, results when lines, instead of a single point focus, results oblique rays of light from an object in the astigmatism [49] periphery strike the lens obliquely Two focal lines are produced from each single object point The dioptric difference between these two focal lines is known as the astigmatic error of the lens Rays of light striking the tangential, or radial, plane of the lens come to a line focus at the tangential focus The resultant focal line is perpendicular to the actual tangential plane Rays striking the sagittal, or the equatorial, plane of the lens come to a line focus at the sagittal focus This focal line is perpendicular to the sagittal plane Both of these planes are shown in Figure 427
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