Under the skin of polishing - from nano to macro

皮肤下的抛光——从纳米到宏观

• 批准号: EP/V029304/1
• 负责人: David Walker
• 金额: $ 66.52万
• 依托单位: University of Huddersfield
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2021
• 资助国家: 英国
• 起止时间: 2021 至 无数据
• 项目状态: 未结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FV029304%2F1
• 关键词: Under; skin; polishing; nano; macro

This proposal brings together experts in complementary areas of physics, chemistry and engineering, to explore new science with potentially high practical impact.Processing glass and similar materials to precise, polished surfaces is the "hidden gem" behind many products and services we take for granted - both in precise control of the distribution of light (e.g. anti-glare headlamps), or to focus light in imaging. From medical X-ray cameras to satellite optics, precise, smooth surfaces are required, with surface errors but small fractions of a micron (maybe 1/1000 the width of a human hair), with roughness down to a few atoms. Also, highly localised defects can scatter light, reducing contrast, or lead to component failure in high-power laser applications. Polishing 'rubs' surfaces to remove damage from prior hard-grinding, and then controls surface-contours to meet design requirements. Historically, these steps were performed by highly-skilled craftspeople, who are in ever-shorter supply as they retire. Modern CNC machines now take much of the drudgery out, but even so, multiple polish/measure cycles are needed to reach refined levels of quality. The basic reason is that, after some 400 years of optical manufacture, the underlying 'rubbing' processes are still far from perfectly understood. A practical setup typically deploys some kind of rotating tool, fed with a liquid slurry containing a fine abrasive powder. The tool moves over a glass surface, often with complex contours. Details of fluid-flow at the microscopic level between tool and glass are complex, and control local interactions of individual abrasive particles with the glass. Then, at the atomic ('nano') scale, chemical-attack, plastic-flow and brittle-fracture perform a complex 'dance', controlling how material is removed.Prior work at various institutions has tended to focus on fluid flow OR nano-scale removal, representing distinct disciplines. But, modelling fluid-flow alone (computational fluid dynamics) omits chemistry and fracture-mechanics. Conversely, nano-scale molecular dynamics omits important fluid-flow issues. What nobody has done before, as we propose, is to combine these distinct approaches, supported by real-time process-monitoring data, and high-performance computing. Then CFD can provide molecular dynamics with predicted particle-trajectories, and particles in CFD can be treated as chemically-reactive rather than inert. The models can then by brought together in a unified large-scale and predictive macro model of removal-processes. Often, scientific breakthroughs arise at the INTERFACES between disciplines - precisely where this proposal focusses.This model will be further developed through polishing trials of complete surfaces, drawing on real-time process-data to predict removal, and post-process measurement of what material has been removed where, plus any defects. This promises to reveal how a surface progresses in real-time, when it is smothered with slurry and invisible to direct inspection. Processes can then be tuned 'on the fly' to keep removal on-target, and improve accuracy of the result. Our aim is then to reduce the number of process cycles required, and give insight into why defects arise and how to control them. In implementing the above, the mathematical and computer models developed at nano, micro and macro scales will describe fundamental aspects of molecules and fluids. This will be generally applicable, including different materials and abrasives. Another important application arises where the methods could be transformative - processes underlying materials wearing in mechanical systems (bearings, slide-ways, human joint-implants etc). So, what starts out as fundamental research into "intentional wear" in processes such as polishing, promises to have a profoundly significant impact on our understanding and control of "incidental wear" in things that rub - and wear-out - in everyday life!

该提案汇集了物理，化学和工程互补领域的专家，以探索具有潜在的实际影响的新科学。对玻璃和类似的材料进行处理，与精确的，抛光的表面相似的材料是我们授予的许多产品和服务背后的“隐藏宝石” - 既可以精确地控制光线的分布（例如，反亮型头球的精确控制）（例如，反亮型灯泡），或者是景点。从医疗X射线摄像机到卫星光学元件，需要精确，光滑的表面，具有表面误差，但微米的小部分（也许是人毛的宽度为1/1000），粗糙度降至几个原子。同样，高度局部的缺陷可以散射光线，减少对比度或导致高功率激光应用中的组件故障。抛光“摩擦”表面以消除先前硬磨碎的损坏，然后控制表面库以满足设计要求。从历史上看，这些步骤是由高技能的手工艺人进行的，他们退休时供应越来越短。现代的CNC机器现在将大部分繁琐的方法淘汰了，但是即使如此，还需要多个波兰/测量周期才能达到精制的质量水平。基本原因是，经过大约400年的光学制造，基础的“摩擦”过程仍然远远无法完全理解。实用的设置通常部署某种旋转工具，并用含有细磨粉粉的液体浆液喂食。该工具在玻璃表面上移动，通常具有复杂的轮廓。工具和玻璃之间微观水平上流体流的细节很复杂，并控制单个磨料颗粒与玻璃的局部相互作用。然后，在原子（'nano'）量表上，化学攻击，塑料流和脆性骨折执行了复杂的“舞蹈”，控制了如何去除材料的方式。各个机构的优点工作倾向于集中于流体流量或纳米尺度上的去除，代表不同的学科。但是，单独建模流体流（计算流体动力学）会忽略化学和破裂力学。相反，纳米级分子动力学忽略了重要的流体流问题。正如我们所建议的那样，以前没有人做的是结合这些不同的方法，并由实时过程监测数据和高性能计算支持。然后，CFD可以提供预测的粒子 - 对象，并且CFD中的颗粒可以视为化学反应性而不是惰性。然后，这些模型可以通过在统一的大规模和预测性宏观模型中聚集在一起。通常，科学的突破是在学科之间的界面上产生的 - 正是该建议重点关注的地方。该模型将通过抛光完整表面的抛光试验进一步开发，利用实时过程数据以预测去除的实时过程以及后期制作的测量，以删除哪些材料已被删除的地方，以及任何缺陷。这有望揭示当表面被泥浆窒息而无形的直接检查时，表面如何实时进展。然后可以“飞行”调整过程，以保持目标脱毛，并提高结果的准确性。然后，我们的目标是减少所需过程周期的数量，并深入了解为什么出现缺陷以及如何控制它们。在实施上述情况时，在Nano开发的数学和计算机模型，微观和宏观尺度将描述分子和流体的基本方面。这通常适用，包括不同的材料和磨料。出现了另一个重要的应用，这些方法可能是变换的 - 机械系统（轴承，滑动通道，人类关节植物等）中佩戴的材料的基础材料。因此，最初是在诸如抛光之类的过程中对“故意磨损”的基本研究，有望在日常生活中对我们对“偶然磨损”的理解和控制的理解和控制产生深远的影响！

项目成果

X-ray luminescence and characteristics of potassium-doped cesium iodide film

• DOI: 10.1016/j.optmat.2024.115021
• 发表时间: 2024-02-05
• 期刊: OPTICAL MATERIALS
• 影响因子: 3.9
• 作者: Wu，Hsing-Yu;Shen，Li -Siang;Hsu，Jin-Cherng
• 通讯作者: Hsu，Jin-Cherng

Bridging the Divide Between Iterative Optical Polishing and Automation

• DOI: 10.1007/s41871-023-00197-3
• 发表时间: 2023-07
• 期刊: Nanomanufacturing and Metrology
• 作者: David Walker;J. I. Ahuir-Torres;Yasemin Akar;Paul A. Bingham;Xun Chen;Michal Darowski;O. Fähnle;Philippe Gambron;Frankie F. Jackson;Hongyu Li;Luke Mason;Rakesh Mishra;Abdullah Shahjalal;Guoyu Yu

Investigation of surface imperfection in freeform optics with high-order XY polynomial design

• DOI: 10.1007/s00170-023-12738-7
• 发表时间: 2023-12
• 期刊: The International Journal of Advanced Manufacturing Technology
• 作者: Sumit Kumar;Wenbin Zhong;Guoyu Yu;Jufan Zhang;W. Zeng;Xiangqian Jiang

Towards Data-Driven Material Removal Rate Estimation in Bonnet Polishing

• DOI: 10.1109/iccma59762.2023.10375024
• 发表时间: 2023-11
• 期刊: 2023 11th International Conference on Control, Mechatronics and Automation (ICCMA)
• 作者: Michal Darowski;Muhammad Faisal Aftab;Hongyu Li;David Walker;Guoyu Yu;Chenghui An;C. W. Omlin

Sub-aperture polishing of glass using precessed bonnets in non-Newtonian fluids

在非牛顿流体中使用加工后的阀盖对玻璃进行亚孔径抛光

• 发表时间: 2022
• 作者: Li, Y