Abstract The tool wear characteristics of the hydrodynamic polishing process under various lubricating conditions are examined in this study. Both the experimental and theoretical studies will be done in this paper. In the experimental study, the relationships between tool wear and its possible influential factors will be examined. In the theoretical study, the mathematical model will be established to interpret the qualitative and quantitative relationships between tool wear characteristics and various operating parameters. For the experimental study, a series of experiments will be done to investigate the effect of various factors on the tool wear and machining rate, under non-contact or semi-contact lubricating condition. The factors may include the tool¡¦s angular speed, the applied load, the tool¡¦s surface irregularities, the slurry viscosity, and the properties of tool, workpiece and abrasive particle (such as surface energy). To establish the mathematical model, the principle of dynamics, law of minimum potential energy and elasto-hydrodynamic lubricating theorem of hydrodynamic polishing process are adopted to derive the removal rate model of a particle under differential contact conditions or under various material parameters (such as surface energies or speed constants) from the energy point of view. In addition, the wear rate of tool is to be analyzed. To deal with the random nature of tool¡¦s surface irregularities, the probability theory is applied to calculate the average wear rate of tool, under semi-contact or non-contact condition or under various material parameters. It is shown that both the tool waviness and radius of tool curvature changed and had specific trends in the wear process. Especially, the wear rate of tool under semi-contact lubricating condition was not necessarily large than that under the non-contact one. The experimental data indicated that the effects of tool wear on machining rate highly depended on the lubricating condition of tool. The trend of machining rate versus accumulated machining time under non-contact lubricating condition was very different from that under the semi-contact one. A mathematical model relating the removal capability of an abrasive particle at the tool¡¦s or workpiece¡¦s surface and various operating parameters are proposed. The qualitative properties of removal capability the under different material parameters and various contact conditions are obtained by the computer simulations. The analysis indicates that the relationships between the removal capability and various material parameters (such as surface energies of adhesion or operating conditions) are not monotonic. Under the contact condition, it is shown that the tool¡¦s surface energy of adhesion and the speed constant has a negative effect on the removal capability at tool¡¦s surface. On the other hand, the surface energy of adhesion on work and the speed constants have a positive effect on the removal capability at tool¡¦s surface. For the workpiece, the converse implications are also true. Three types of patterns for removal capability at tool¡¦s surface due to the degree of embedding of a particle were obtained. There are increase or first increase then decrease or decrease directly, respectively. Under non-contact condition, it is shown that the removal capability has a negative relationship with local film thickness. In addition, a mathematical model relating the tool or work piece wear rate and various operating parameters are also proposed. The qualitative properties of tool wear rate under various lubricating conditions are obtained by the simple statistic analysis. The analysis indicates that the relationships between tool and workpiece wear rate and various parameters are also not monotonic. Under non-contact condition, the tool or workpiece wear rate will first increase then decrease due to the tool periphery speed increase. The magnitude of wear rate will decrease or increase due to the material parameters. Under the semi-contact condition, the up-and-down trend is also occurred in the relationship between tool or workpiece wear rate and the tool periphery speed. Accordingly, the relationships between wear rate and tool periphery speed, in a lubricating range covering the non-contact and semi-contact conditions, will reveal a twin-peak pattern. Generally, the workpiece wear rate under the semi-contact condition is not less than the non-contact one. However, the tool wear rate under the semi-contact condition is not necessarily large than the non-contact one. For a specific condition, under the semi-contact condition, the magnitude of the tool wear rate under different speed will increase or decrease by choosing different tool¡¦s surface adhesive energy and speed constant and the relationship between tool wear rate and tool speed will become complex. The wear rate could increase or decrease significantly. In other word, the tool wear rate under the semi-contact condition may be smaller or large than the non-contact one. Hence, a tool with large surface adhesive energy and speed constant should have a lower tool wear rate or higher work wear rate under certain lubricating regime. Finally, the experimental study tests that the proposed model is closely related with the experimental data. The study showed that the qualitative trends of experimental data are consistent with the analytical predictions. Some of the qualitative relationships between tool wear and machining rate could be properly explained from the elasto-hydrodynamic lubrication theorem and the proposed wear theorem for hydrodynamic polishing process.

Abstract The removing efficiency of surface roughness for the hydrodynamic polishing process under semi-contact lubricating condition was investigated in this thesis. The experimental relationships between surface roughness and polishing were first examined. From the relationships, the potential influential factors of the removing efficiency and the magnitude of surface roughness were identified. Finally, a mathematical model that was related to the removing efficiency and the magnitude of surface roughness was proposed. Based on the experimental study, it was shown that the surface roughness would be rapidly reduced at the beginning by polishing process and then hardly improved afterward. This trend implied that surface roughness would not be completely removed during the polishing process. It was proposed that the amplitude and wavelength of surface roughness would affect the removing efficiency of surface roughness. Further, the removing efficiency was not sensitive to the tool velocity. From the mathematical model, several points were concluded. First, the removing efficiency was positively proportional to the amplitude of surface roughness. Second, the removing efficiency was inversely to the amplitude of surface roughness. Third, the removing efficiency was inverse proportional to a waviness of tool surface. Fourth, the removing efficiency was not sensitive to tool velocity. Finally, there existed an achievable minimum surface roughness for a surface with specific wavelength. The magnitude of a minimum surface roughness was shown to be proportional to the wavelength of work surface.

The ultimate value of surface roughness and its characteristic for the polishing process was investigated in this thesis. To find out the nature of ultimate surface roughness by means of the hydrodynamic polishing process and can be used for all polishing method. A preliminary mathematical model that was proposed to explain the ultimate surface roughness proceedings and a series of experiments was planed to verify suitable of this model. Starting with the rule for ultimate surface roughness happened. The assumption that abrasive particle at roughness peak and valley machining capability differ less than one atom, the ultimate surface roughness be attained. We can propose the mathematical model of ultimate surface roughness based on this rule and the previous study of hydrodynamic polishing process. Following by useing the computer simulation to help us exploring ultimate surface roughness characteristic and testing experiments fit for the forecasting. Finally, we explain reasons that cause the experiment results not agree with the model anticipation and propose better lubrication condition to polish the optimum surface.

This thesis is aimed to apply cylindrical polishing system to a large flat workpiece (ex:wafer) to obtain high degree of planarization, low surface roughness and no crack layer. First, a mathematical model is presented which describes the axially symmetric form error compensation by cylindrical polishing process. The dwelling time-distribution of tool and the machining depth distribution are solved using the methods of simultaneous equations and least square error with non-negativity constraints. Then, using the simulation analysis and experimental method to examine the machining rate distribution effects on machining precision and the dwelling time-distribution of the tool when the workpiece is machining by cylindrical tool. The examined effects will include machining length effect, boundary effect and inclined effect. Under the range of the machining precision required, the approach to smooth the dwelling time-distribution of tool that will benefit layer-by-layer removing strategy. After these analyses, an adequacy dwelling time-distribution of the tool can be designed according to the workpiece form error. In addition, the relative between the machining probability due to the an-isotropic polishing property and surface roughness will be discussed. The contents of this thesis include three parts. First, a mathematical model is presented which describes the axially symmetric form error compensation by cylindrical polishing process. And, the polishing angles and polishing probability of the an-isotropic polishing property will be identified according to the mathematical model. Second, the design of dwelling time-distribution of tool and the analysis of the geometric effects will be discussed by computer simulation. Third, the experimental results will show the suitable of the machining strategy and compare the machining effects with the simulated results. And, the planarization of the workpiece that has axially symmetric form error will be done.

Im Bauwesen kommen verschiedene Kantenausführungsarten von Glas zum Einsatz. In Abhängigkeit ihrer Art erfüllen sie Anforderungen an den Schnittschutz, die Maßhaltigkeit und die Ästhetik. Nach DIN 1249-11 erfolgt die Einteilung entsprechend des äußeren Erscheinungsbildes in geschnittene (KG), gesäumte (KGS), maßgeschliffene (KMG), geschliffene (KGN) und polierte (KPO) Kanten. Die mechanische Festigkeit der Glaskante ist jedoch gesondert zu betrachten. Die charakteristische Biegezugfestigkeit von Glas ist maßgeblich von dessen Oberflächenzustand abhängig. Die Herstellung und Bearbeitung der Kante erfolgt durch einen Materialeingriff mit harten Schneid- und Schleifwerkzeugen. Dabei werden die Oberflächenbeschaffenheit verändert und das Bruchverhalten beeinflusst. Bisher regelt die europäische Normung Kantenfestigkeiten in der Bemessung in Form von Beiwerten, welche die charakteristische Biegezugfestigkeit pauschal oder in Abhängigkeit der Kantenausführungsart abmindern. Bestehende Untersuchungen zeigen jedoch wesentliche Unterschiede der Kantenfestigkeit in Abhängigkeit von Kantenausführungsart und Herstellungsprozess. Die Bemessungswerte der Kantenfestigkeit gelten als untere Grenze der auf dem Markt verfügbaren Qualitäten. Wissenschaftlich belegte Beurteilungen der visuellen Kantenqualität mit Einschätzung ihrer mechanischen Festigkeit liegen bisher nur für die geschnittene Kantenausführung vor. Für den industriellen Schneidprozess wurden auf Basis systematischer Untersuchungen Parameter detektiert, die sich positiv auf die Kantenfestigkeit auswirken. Es ist unbekannt, wie sich der Oberflächeneingriff durch Schleif- und Polierprozesse auf die mechanische Festigkeit der dabei hergestellten Kantenausführungsarten auswirkt und welche Ursachen dafür zu benennen sind. Zudem fehlen geregelte, einheitliche Methoden, um die Kantenqualitäten optisch und mechanisch zu erfassen. Im Rahmen dieser Arbeit wird eine Versuchsmethodik entwickelt, welche über mikroskopische Analysen und Bruchversuche die Erfassung vergleichbarer optischer und mechanischer Kennwerte ermöglicht. In einer Zusammenführung der Methoden erfolgt erstmalig die Charakterisierung bruchverursachender Fehlstellen und deren Rückführung auf den Entstehungsort im Herstellungsprozess. Anhand einer systematischen Untersuchung verschiedener Kantenausführungsarten eines Herstellers findet die Erprobung und Bewertung der entwickelten Versuchsmethodik statt. Anschließend werden Prozessanpassungen zur Fehlstellenreduzierung vorgenommen und in Bezug auf eine Steigerung der Kantenfestigkeit untersucht. Weitere Analysen des Herstellungsprozesses eines zweiten Herstellers erfolgen für verschieden polierte Kanten. Entsprechend der ermittelten bruchverursachenden Fehlstellen werden Hypothesen für zukünftige Untersuchungen abgeleitet. Die Erkenntnisse dieser Arbeit stellen die wissenschaftliche Grundlage für verfahrenstechnische Handlungsempfehlungen zur Herstellung von Glaskanten dar. Der aktuelle Stand bedeutender europäischer Bemessungsregeln wird für abschließende normative Empfehlungen einbezogen. Die gesäumte Kante ergibt sich beim ersten Hersteller als Kantenausführungsart mit der höchsten Kantenfestigkeit. Für die maßgeschliffene, geschliffene und polierte Kante ergeben sich im Vergleich zur geschnittenen und gesäumten Kante geringere Festigkeiten. Die Untersuchung der polierten Kantenausführung des zweiten Herstellers ergibt, verglichen mit der polierten Kante des ersten Herstellers, eine höhere Kantenfestigkeit. Daraus leitet sich der Einfluss der Maschinenkonfiguration als einflussreicher Prozessparameter ab. Die Analyse der bruchverursachenden Fehlstellen zeigt, dass höherfeste Kanten mit einer Reduzierung von mikroskopisch erfassbaren Fehlstellen für die geschnittene, gesäumte und polierte Kante korrelieren. Darüber hinaus gewährleisten die in dieser Arbeit entwickelten Fehlstellenanalysen eine Detektion festigkeitsmindernder Fehlstellen, die auf eine Einbringung nach der Herstellung hindeuten und somit die Notwendigkeit von Kantenschutzmaßnahmen nach sich ziehen. Definitionen allgemeingültiger Prozessparameter in Schleif- und Polierprozessen, die eine positive Auswirkung auf die Kantenfestigkeit bearbeiteter Kanten haben, sind bisher in der Literatur nicht vorhanden. Die in dieser Arbeit beschriebenen Ergebnisse dienen als Grundlage zur Optimierung der Prozessparameter für hohe Kantenfestigkeiten. Experimentelle Nachweise der mechanischen Festigkeit sind dabei unabdingbar. Die Kantenqualität ist in optische und mechanische Eigenschaften zu unterscheiden. Die optisch als am hochwertigsten geltende polierte Kante geht nicht zwangsläufig mit einer hohen Kantenfestigkeit einher, was eine in der Praxis weitverbreitete Annahme widerlegt. In diesem Kontext leistet die vorliegende Arbeit einen Beitrag zum Verständnis der Herstellungsprozesse und der Bemessung von Glasbauteilen, um den steigenden Anforderungen im konstruktiven Glasbau gerecht zu werden.:1 Einleitung 2 Grundlagen zu Glaskanten 3 Wissensstand zur Kantenfestigkeit 4 Entwicklung einer Versuchsmethodik zur Erfassung der Kantenqualität 5 Systematische Analyse der Kantenqualität eines Herstellers 6 Einfluss von Prozessparametern auf die Kantenfestigkeit nach Kantenausführungsart 7 Diskussion der Ergebnisse 8 Bemessungsansätze für Glaskanten 9 Handlungsempfehlungen 10 Zusammenfassung und Ausblick 11 Literatur / In the building industry, different types of glass edges are used. Depending on their type, they fulfil requirements for cutting protection, dimensional accuracy, and aesthetics. According to DIN 1249-11, the classification is based on the visual appearance and includes cut (KG), arrissed (KGS), ground (KMG), smooth ground (KGN), and polished (KPO) edge finishing type. However, the mechanical strength of the glass edge requires additional consideration. The characteristic bending tensile strength of glass depends mostly on its surface condition. During production and processing the edge comes in contact with hard tools, which modifies the optical appearance and influences the strength. Presently, the European standardization regulates the edge strength in the design by general coefficients, which reduce the characteristic bending tensile strength depending on the edge finishing type. Existing studies show a large range of values in edge strength depending on the edge finishing and the manufacturer. The design edge strength considers the lower limits of the available glass edge finishing types. Scientifically based evaluation of the optical edge quality with assessment of the mechanical strength is available only for the cut edge. For the industrial cutting process, parameters have been determined on the basis of systematic investigations that show a positive influence on edge strength. It is still unknown how surface interferences by grinding and polishing processes affect the edge strength of processed glass edges and what are the underlying mechanisms. In addition, there is a lack of unified methods for assessing the mechanical edge quality. Within the scope of this work, a test methodology is developed that enables the determination of comparable optical and mechanical characteristics by means of microscopic analysis and destructive tests. A combination of different methods is used to characterize fracture-causing defects and to identify the location of their creation in the manufacturing process. The testing methods are approved and evaluated on the basis of a systematic examination of different edge types of one manufacturer. Subsequently, process adjustments for defect reduction are conducted and investigated with regard to an increase in edge strength. Moreover, the manufacturing process of various polished edge types of a second manufacturer are examined. Thereby, fracture-causing flaws are identified and hypotheses for future investigations are derived that form the basis for processing recommendations for the manufacturing of glass edges. The current status of relevant European design rules is finally discussed for normative recommendations. The arrised edge finishing type revealed the highest edge strength. For the ground, smooth ground, and polished edges, the edge strength is lower compared to the cut and arrised edges. The examination of the polished edge from the second manufacturer resulted in a higher edge strength compared to the polished edge from the first manufacturer. Therefore, the influence of the machine configuration is derived as an impacting process parameter. The analysis of fracturecausing defects has confirmed that a higher edge strength correlates with a reduction in microscopically detectable defects for the cut, arrised, and polished edge types. The defect analysis also enables the detection of strength-reducing defects that are introduced after production and require edge protection measures. Definitions of generally valid process parameters in grinding and polishing that positively affect the edge strength of machined edges are unknown. However, the results of this work enable manufacturers to optimize processes specific to their (manufacturing) process in order to ensure high values of edge strength. Nonetheless, experimental verifications are indispensable in this respect. Optical and mechanical properties of glass edges need to be considered separately. For example, the polished edge is considered to offer the highest optical quality. However, contrary to a widespread assumption, it does not necessarily display high edge strength. A better understanding of the manufacturing processes and the verification of edge strength are necessary for the design to meet the increasing demands in structural glass applications.:1 Einleitung 2 Grundlagen zu Glaskanten 3 Wissensstand zur Kantenfestigkeit 4 Entwicklung einer Versuchsmethodik zur Erfassung der Kantenqualität 5 Systematische Analyse der Kantenqualität eines Herstellers 6 Einfluss von Prozessparametern auf die Kantenfestigkeit nach Kantenausführungsart 7 Diskussion der Ergebnisse 8 Bemessungsansätze für Glaskanten 9 Handlungsempfehlungen 10 Zusammenfassung und Ausblick 11 Literatur