A new integrated polishing process design for plastic mold steel to mirror-like surface

Abstract

This paper aims to propose the design of a new polishing tool, a clamp with a flexible polishing head (or CFPH) for polishing plastic mold steel. The investigation/evaluation of this new tool’s performance in polishing is also included in this paper. The design of this brand new flexible clamp with a polishing head is, first of all, based on the application of the concept of weakening gap in the study of Fuh [1] increase in the freedom of micro-movement of the clamp is available. Second, various analyses and tests are done by the finite element method (FEM). Then, through the spectrogram, we analyze this tool’s machining characteristics. Furthermore, by the performance on large waves, medium waves, and small waves of the workpiece, we evaluate the working efficiency and set up a set of polishing strategies. This module of machining strategy process contains the combination of cutting and polishing one kind or multi-kind machining modes and the complementary precision processing methods. Finally, we propose a set of polishing integration process skills specifically on S-STAR*. We also verify our analysis with 3D profiles and the surface roughness measurement instrument. These verified analyses show that roughness and shape precision can be reached to Ra0.006, Rmax0.08, and PV0.084 μm respectively. This new invention, by the spectrum analysis, can significantly improve large wavelength accuracy up to 83.9 %, medium wavelength accuracy 82.5 %, and small wavelength accuracy 80.2 %. To conclude, we aim to set up a mirror-like surface polishing tool for plastic mold steel. This proposal is prudentially verified and should be considered theoretically and practically successful.