Magnetorheological finishing (MRF) is a precision surface finishing technology. Optical surfaces are polished in a computer-controlled magnetorheological (MR) finishing slurry. Unlike conventional rigid lappolishing, the MR fluid's shape and stiffness can be magnetically manipulated and controlled in real time. The optic's final surface form and finishing results are predicted through the use of computer algorithms.
Literature
W.I. Kordonski (2014). "Magnetorheological Fluid-Based High Precision Finishing Technology." Magnetorheology: Advances and Applications, Norman M. Wereley, Ed., RSC Smart Materials, Cambridge, UK, Chapter 11, 261–277. DOI:10.1039/9781849737548-00261
S.D. Jacobs, W.I. Kordonski, I.V. Prokhorov, D. Golini, G.R. Gorodkin, T.D. Strafford (2002). "Deterministic Magnetorheological Finishing." US Patent: US5449313A
Shorey et al. "Experiments and Observations Regarding the Mechanisms of Glass Removal in Magnetorheological Finishing", abstract and full text (pdf)
Chunlin Miao, et al., "Shear stress in magnetorheological finishing for glasses," Applied Optics 48, 2585-2594 (2009)
Chunlin Miao, et al., "Process parameter effects on material removal in magnetorheological finishing of borosilicate glass," Applied Optics 49, 1951-1963 (2010)
Photonics is the physical science and application of light (photon) generation, detection, and manipulation through emission, transmission, modulation, signal processing, switching, amplification, and sensing. Though covering all light's technical applications over the whole spectrum, most photonic applications are in the range of visible and near-infrared light. The term photonics developed as an outgrowth of the first practical semiconductor light emitters invented in the early 1960s and optical fibers developed in the 1970s.
Machining is a process in which a material is cut to a desired final shape and size by a controlled material-removal process. The processes that have this common theme are collectively called subtractive manufacturing, in contrast to additive manufacturing, which uses controlled addition of material. Exactly what the "controlled" part of the definition implies can vary, but it usually implies the use of machine tools.
Laser cutting is a technology that uses a laser to vaporize materials, resulting in a cut edge. While typically used for industrial manufacturing applications, is now used by schools, small businesses, architecture, and hobbyists. Laser cutting works by directing the output of a high-power laser most commonly through optics. The laser optics and CNC are used to direct the material or the laser beam generated. A commercial laser for cutting materials uses a motion control system to follow a CNC or G-code of the pattern to be cut onto the material. The focused laser beam is directed at the material, which then either melts, burns, vaporizes away, or is blown away by a jet of gas, leaving an edge with a high-quality surface finish.
A magnetorheological fluid is a type of smart fluid in a carrier fluid, usually a type of oil. When subjected to a magnetic field, the fluid greatly increases its apparent viscosity, to the point of becoming a viscoelastic solid. Importantly, the yield stress of the fluid when in its active ("on") state can be controlled very accurately by varying the magnetic field intensity. The upshot is that the fluid's ability to transmit force can be controlled with an electromagnet, which gives rise to its many possible control-based applications. Extensive discussions of the physics and applications of MR fluids can be found in a recent book.
Ferrofluid is a liquid that is attracted to the poles of a magnet. It is a colloidal liquid made of nanoscale ferromagnetic, or ferrimagnetic, particles suspended in a carrier fluid. Each magnetic particle is thoroughly coated with a surfactant to inhibit clumping. Large ferromagnetic particles can be ripped out of the homogeneous colloidal mixture, forming a separate clump of magnetic dust when exposed to strong magnetic fields. The magnetic attraction of tiny nanoparticles is weak enough that the surfactant's Van der Waals force is sufficient to prevent magnetic clumping or agglomeration. Ferrofluids usually do not retain magnetization in the absence of an externally applied field and thus are often classified as "superparamagnets" rather than ferromagnets.
A smart fluid is a fluid whose properties can be changed by applying an electric field or a magnetic field.
Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing material through a die of the desired cross-section. Its two main advantages over other manufacturing processes are its ability to create very complex cross-sections; and to work materials that are brittle, because the material encounters only compressive and shear stresses. It also creates excellent surface finish and gives considerable freedom of form in the design process.
Electrorheological (ER) fluids are suspensions of extremely fine non-conducting but electrically active particles in an electrically insulating fluid. The apparent viscosity of these fluids changes reversibly by an order of up to 100,000 in response to an electric field. For example, a typical ER fluid can go from the consistency of a liquid to that of a gel, and back, with response times on the order of milliseconds. The effect is sometimes called the Winslow effect after its discoverer, the American inventor Willis Winslow, who obtained a US patent on the effect in 1947 and wrote an article published in 1949.
Diamond turning is turning using a cutting tool with a diamond tip. It is a process of mechanical machining of precision elements using lathes or derivative machine tools equipped with natural or synthetic diamond-tipped tool bits. The term single-point diamond turning (SPDT) is sometimes applied, although as with other lathe work, the "single-point" label is sometimes only nominal. The process of diamond turning is widely used to manufacture high-quality aspheric optical elements from crystals, metals, acrylic, and other materials. Plastic optics are frequently molded using diamond turned mold inserts. Optical elements produced by the means of diamond turning are used in optical assemblies in telescopes, video projectors, missile guidance systems, lasers, scientific research instruments, and numerous other systems and devices. Most SPDT today is done with computer numerical control (CNC) machine tools. Diamonds also serve in other machining processes, such as milling, grinding, and honing. Diamond turned surfaces have a high specular brightness and require no additional polishing or buffing, unlike other conventionally machined surfaces.
An aspheric lens or asphere is a lens whose surface profiles are not portions of a sphere or cylinder. In photography, a lens assembly that includes an aspheric element is often called an aspherical lens.
An optical fiber is a flexible, transparent fiber made by drawing glass (silica) or plastic to a diameter slightly thicker than that of a human hair. Optical fibers are used most often as a means to transmit light between the two ends of the fiber and find wide usage in fiber-optic communications, where they permit transmission over longer distances and at higher bandwidths than electrical cables. Fibers are used instead of metal wires because signals travel along them with less loss; in addition, fibers are immune to electromagnetic interference, a problem from which metal wires suffer. Fibers are also used for illumination and imaging, and are often wrapped in bundles so they may be used to carry light into, or images out of confined spaces, as in the case of a fiberscope. Specially designed fibers are also used for a variety of other applications, some of them being fiber optic sensors and fiber lasers.
Optical manufacturing and testing spans an enormous range of manufacturing procedures and optical test configurations.
A magnetorheological damper or magnetorheological shock absorber is a damper filled with magnetorheological fluid, which is controlled by a magnetic field, usually using an electromagnet. This allows the damping characteristics of the shock absorber to be continuously controlled by varying the power of the electromagnet. Fluid viscosity increases within the damper as electromagnet intensity increases. This type of shock absorber has several applications, most notably in semi-active vehicle suspensions which may adapt to road conditions, as they are monitored through sensors in the vehicle, and in prosthetic limbs.
Ultrasonic machining is a subtractive manufacturing process that removes material from the surface of a part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine abrasive particles. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. The fine abrasive grains are mixed with water to form a slurry that is distributed across the part and the tip of the tool. Typical grain sizes of the abrasive material range from 100 to 1000, where smaller grains produce smoother surface finishes.
Grinding is a type of abrasive machining process which uses grinding wheel as cutting tool.
Precision glass moulding is a replicative process that allows the production of high precision optical components from glass without grinding and polishing. The process is also known as ultra-precision glass pressing. It is used to manufacture precision glass lenses for consumer products such as digital cameras, and high-end products like medical systems. The main advantage over mechanical lens production is that complex lens geometries such as aspheres can be produced cost-efficiently.
A metamaterial absorber is a type of metamaterial intended to efficiently absorb electromagnetic radiation such as light. Furthermore, metamaterials are an advance in materials science. Hence, those metamaterials that are designed to be absorbers offer benefits over conventional absorbers such as further miniaturization, wider adaptability, and increased effectiveness. Intended applications for the metamaterial absorber include emitters, photodetectors, sensors, spatial light modulators, infrared camouflage, wireless communication, and use in solar photovoltaics and thermophotovoltaics.
Laser drilling is the process of creating thru-holes, referred to as “popped” holes or “percussion drilled” holes, by repeatedly pulsing focused laser energy on a material. The diameter of these holes can be as small as 0.002”. If larger holes are required, the laser is moved around the circumference of the “popped” hole until the desired diameter is created; this technique is called “trepanning”.
Magnetic field-assisted finishing, sometimes called magnetic abrasive finishing, is a surface finishing technique in which a magnetic field is used to force abrasive particles against the target surface. As such, finishing of conventionally inaccessible surfaces is possible. Magnetic field-assisted finishing (MAF) processes have been developed for a wide variety of applications including the manufacturing of medical components, fluid systems, optics, dies and molds, electronic components, microelectromechanical systems, and mechanical components.
An optical head-mounted display (OHMD) is a wearable device that has the capability of reflecting projected images as well as allowing the user to see through it, similar to augmented reality technology. OHMD technology has existed since 1997 in various forms, but despite a number of attempts from industry, has yet to be commercialised.
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