Method and apparatus for micro-machining a surface
First Claim
1. A method of micro-machining a surface of a workpiece having a complex surface profile including desired profile features and finer undesired profile features to be removed, comprising:
- providing a formable polishing tool, said formable polishing tool comprises a thermoplastic polymer selected from the group consisting of high density polyethylene or ultra high molecular weight polyethylene, said thermoplastic polymer having a solid filler additive for controlling the thermal conductivity and speed of sound in said formable polishing tool;
shaping said formable polishing tool using either the workpiece itself or a replica of the workpiece to have at least said desired profile features;
andusing said formable polishing tool to micro-machine said workpiece surface to remove said finer undesired profile features while maintaining said desired profile features.
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Abstract
An apparatus and method for micro-machining a surface of a workpiece having a complex surface profile including desired profile features and finer undesired profile features to be removed, including shaping a formable polishing tool using either the workpiece itself or a replica of the workpiece to have at least said desired profile features, and using said formable polishing tool to micro-machine said surface to remove said finer undesired profile features while maintaining said desired profile features. The formable polishing tool can be shaped to have at least said desired profile features by pressing the formable polishing tool against either the workpiece itself or the replica of the workpiece when the formable polishing tool is in a formable state, and the formable polishing tool can be used for micro-machining when the formable polishing tool is in a solid state.
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Citations
23 Claims
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1. A method of micro-machining a surface of a workpiece having a complex surface profile including desired profile features and finer undesired profile features to be removed, comprising:
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providing a formable polishing tool, said formable polishing tool comprises a thermoplastic polymer selected from the group consisting of high density polyethylene or ultra high molecular weight polyethylene, said thermoplastic polymer having a solid filler additive for controlling the thermal conductivity and speed of sound in said formable polishing tool; shaping said formable polishing tool using either the workpiece itself or a replica of the workpiece to have at least said desired profile features; and using said formable polishing tool to micro-machine said workpiece surface to remove said finer undesired profile features while maintaining said desired profile features. - View Dependent Claims (2, 3, 4, 5, 6, 7, 21)
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8. A method of making a component from a workpiece having a complex surface profile including desired profile features and finer undesired profile features to be micro-machined, comprising:
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providing a formable polishing tool, said formable polishing tool comprises a thermoplastic polymer selected from the group consisting of high density polyethylene or ultra high molecular weight polyethylene, said thermoplastic polymer having a solid filler additive for controlling the thermal conductivity and speed of sound in said formable polishing tool; shaping said formable polishing tool using either the workpiece itself or a replica of the workpiece to have at least said desired profile features; then using said formable polishing tool to micro-machine said finer undesired profile features while maintaining said desired profile features; and then forming the component using the workpiece. - View Dependent Claims (9, 10, 11, 12, 13, 22)
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14. A micro-machining apparatus for micro-machining a workpiece having a complex surface profile including desired profile features and finer undesired profile features to be micro-machined, the apparatus comprising:
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a formable polishing tool configured to micro-machine said finer undesired profile features while maintaining said desired profile features, said formable polishing tool comprises a thermoplastic polymer selected from the group consisting of high density polyethylene or ultra high molecular weight polyethylene, said thermoplastic polymer having a solid filler additive for controlling the thermal conductivity and speed of sound in said formable polishing tool; a transducer for driving said polishing tool; wherein the formable polishing tool has been shaped to have at least said desired profile features using either the workpiece itself or a replica of the workpiece. - View Dependent Claims (15, 16, 17, 23)
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18. A formable polishing tool for use with a micro-machining apparatus for micro-machining a workpiece having a complex surface profile including desired profile features and finer undesired profile features to be micro-machined,
said formable polishing tool is configured to micro-machine said finer undesired profile features while maintaining said desired profile features, said formable polishing tool having been shaped when in the formable state to have at least said desired profile features by using either the workpiece itself or a replica of the workpiece, wherein said formable polishing tool comprises a thermoplastic polymer selected from the group consisting of high density polyethylene or ultra high molecular weight polyethylene, said thermoplastic polymer having a solid filler additive for controlling the thermal conductivity and speed of sound in said formable polishing tool.
Specification