Shape-adaptive magnetic field-assisted batch polishing of three-dimensional surfaces

The increasing demand of the superfinished three-dimensional (3D) surfaces has stimulated the development and upgrade of the precision polishing technology. However, current ultra-precision polishing methods usually polish the workpiece one-by-one, leading to low production efficiency and high polishing cost. Even though some batch polishing methods have been developed for polishing a number of workpieces simultaneously, it is difficult for them to obtain high form accuracy, as well as nanometre scale surface roughness. Hence, this paper presents a shape-adaptive magnetic field-assisted batch polishing (SAMABP) method which not only implements nanometre scale batch polishing of 3D surfaces, but also achieves high form maintainability. Firstly, the effect of surface shape on the material removal in magnetic field-assisted batch polishing (MABP) is revealed. Secondly, the shape-adaptive optimization (SAO) algorithm is developed to cater for the effect of the material removal variation on different kinds of surface shapes, based on the kinematic analysis of the magnetic brush in MABP, as well as modelling of the material removal distribution. At last, a series of verification experiments are designed and conducted on convex, concave and structured surfaces to validate the proposed method. The surface roughness of 3D surface was significantly reduced from larger than 100 nm to less than 10 nm or even less than 5 nm in arithmetic surface roughness ( Sa ) after 20 min of polishing. Meanwhile, the surface forms were maintained well, and the deviation of them after polishing were all less than 4 μm in peak-to-valley ( PV ). These results show that the SAMABP method is effective to obtain nanometric surface roughness together with micrometric form accuracy in the batch polishing of 3D surfaces. This study sheds the light for the applications of SAMABP in batch polishing of optical components and moulds, functional structured surfaces, turbine blades, dental crowns, surgical knives, high-end jewelleries, etc. • The effect of surface shape on surface quality in magnetic field-assisted batch polishing (MABP) is revealed. • Material removal model and shape adaptive optimization algorithm are developed to cater for the shape effect. • A novel shape adaptive magnetic field-assisted batch polishing (SAMABP) method is developed. • The SAMABP method is validated on different kinds of 3D surfaces including freeform surfaces. • The SAMABP is found to achieve nanometric surface roughness and micrometre scale form accuracy.