OptiSonic: The Latest in Ultrasonic Machining Technology

Ron Colavecchia11/10/2016

• Why use UltraSonic

• IntelliSonic software

• Tool holder developments

• Test cases

• Questions and Answers

Agenda

2

OptiSonic Grinding Platform

3

• 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

4

OptiSonic Spindle

• All power transfer occurs within the housing.

• Labyrinth seal ensures no coolant gets into housing during machining processes.

• Air Purged housing

6

OptiSonic Tool Holder Overview

OptiSonic Collet Tool Holder Development

0.012”

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

IntelliSonic

Tool Characterization

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

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

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

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.

14

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.

• 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

16

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”

17

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

18

Set up of experiment – Sapphire grinding

Toolpath

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

Figure 4: Surface roughness after 230-270 grit tool

Tool Life Testing

Ultrasonic On

Ultrasonic On

Ultrasonic Off

Ultrasonic Off

13” Diameter Zerodur Light weighing

At least 3 times faster cycle times with OptiSonic

25

• 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

For more Information:

Ron Colavecchia

Office: 585-265-0160

ron@optipro.com

OptiPro Systems, LLC

6368 Dean Parkway

Ontario, NY 14519

585-265-0160

www.optipro.com

Thank You