Modeling an abrasive process to achieve controlled material removal
First Claim
1. A method for controlling an abrasive process comprising:
- generating an open-loop model of a cut rate of an abrasive article type when applied to workpiece type over an abrading period, wherein generating the model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1+R2×
e−
t/T2,where R1 and R2 are constants set according to an initial cut rate for the abrasive article,t equals a length of time that the abrasive article has been applied to the workpiece, andT1 and T2 are time constants; and
abrading a workpiece of the workpiece type with an abrasive article of the abrasive article type in accordance with the model to achieve a substantially constant cut rate.
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Accused Products
Abstract
In general, techniques are described that allow an abrasive manufacturing process to achieve a controlled performance parameter, e.g., an amount of material removal, without requiring the use of feedback controls within the abrasive manufacturing process. For example, a system includes a machine to abrade a workpiece with an abrasive article, and a controller to control the application of the abrasive article to the workpiece by the machine to achieve a substantially constant cut rate for the abrasive article. The controller controls one or more process variables in accordance with an open-loop mathematical model that relates the cut rate of the abrasive article to an application force of the abrasive article to achieve controlled material removal. For example, a constant rate of cut can be achieved or a fixed amount of material can be removed while abrading one or more workpiece in accordance with the model.
49 Citations
51 Claims
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1. A method for controlling an abrasive process comprising:
generating an open-loop model of a cut rate of an abrasive article type when applied to workpiece type over an abrading period, wherein generating the model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1 +R2×
e−
t/T2 ,where R1 and R2 are constants set according to an initial cut rate for the abrasive article, t equals a length of time that the abrasive article has been applied to the workpiece, and T1 and T2 are time constants; and abrading a workpiece of the workpiece type with an abrasive article of the abrasive article type in accordance with the model to achieve a substantially constant cut rate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A system comprising:
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a machine to abrade a workpiece with an abrasive article; and a controller to control the application of the abrasive article to the workpiece by the machine in accordance with an open-loop model to achieve a substantially constant cut rate for the abrasive article; wherein the open-loop model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1 +R2×
e−
t/T2 ,where R1 and R2 are constants set according to an initial cut rate for the abrasive article, t equals a length of time that the abrasive article has been applied to the workpiece, and T1 and T2 are time constants. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36)
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37. A computer-readable medium comprising instructions to cause a programmable controller to direct a machine to abrade a workpiece with an abrasive article in accordance with an open-loop model to achieve a substantially constant cut rate for the abrasive article over an abrading period;
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wherein the open-loop model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1 +R2×
e−
t/T2 ,where R1 and R2 are constants set according to an initial cut rate for the abrasive article, t equals a length of time that the abrasive article has been applied to the workpiece, and T1 and T2 are time constants. - View Dependent Claims (38, 39, 40, 41, 42)
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43. A computer-readable medium comprising data representing an open-loop model for use by a machine to abrade a workpiece with an abrasive article to achieve a substantially constant cut rate for the abrasive article over an abrading period;
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wherein the open-loop model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1 +R2×
e−
t/T2 ,where R1 and R2 are constants set according to an initial cut rate for the abrasive article, t equals a length of time that the abrasive article has been applied to the workpiece, and T1 and T2 are time constants. - View Dependent Claims (44, 45)
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46. A method for controlling an abrasive process comprising:
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generating an open-loop model of a cut rate of an abrasive article type when applied to a workpiece type over an abrading period, wherein generating the model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1 +R2×
e−
t/T2 ,where R1 and R2 are constants set according to an initial cut rate for the abrasive article, t equals a length of time that the abrasive article has been applied to the workpiece, and T1 and T2 are time constants; and abrading a workpiece of the workpiece type with an abrasive article of the abrasive article type in accordance with the model to achieve a controlled amount of material removed from the workpiece during the abrading period. - View Dependent Claims (47, 48)
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49. A method for controlling an abrasive process comprising:
generating an open-loop model of a performance parameter of a type abrasive article type when applied to a type of semiconductor conditioning pad, wherein generating the model comprises computing the cut rate R of the abrasive article as a function of a length of time that the abrasive article has been applied to the workpiece at a substantially constant force in accordance with a first equation as follows;
R=R1×
e−
t/T1 +R2×
e−
t/T2 ,where R1 and R2 are constants set according to an initial cut rate for the abrasive article, t equals a length of time that the abrasive article has been applied to the workpiece, and T1 and T2 are time constants; polishing a plurality of semiconductor wafers with a conditioning pad of the conditioning pad type; and repeatedly abrading the conditioning pad with an abrasive article of the abrasive article type in accordance with the model to remove a substantially equal amount of material from the pad during each of the abradings. - View Dependent Claims (50, 51)
Specification