Polishing spherical BK7 workpieces

with fiber-based tools

Hossein Shahinian
Brigid Mullany

Hossein Shahinian, Brigid Mullany, “Polishing spherical BK7 workpieces with fiber-based tools,” Opt. Eng.
58(9), 092610 (2019), doi: 10.1117/1.OE.58.9.092610.

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 Optical Engineering 58(9), 092610 (September 2019)

Polishing spherical BK7 workpieces with fiber-based tools

Hossein Shahiniana and Brigid Mullanyb,*
a
Micro-LAM Inc., Portage, Michigan, United States
b
University of North Carolina at Charlotte, Department of Mechanical Engineering and Engineering Science, Charlotte, North Carolina,
United States

Abstract. This work is a continuation of previously published work on the application of fiber-based tools in
precision polishing of optical components. Previous publications mainly focused on understanding how fiber-
based tools remove material and the potential of such tools in reducing existing midspatial frequency errors on
planar samples. In this work, an exemplary tool consisting of nylon 6/6 fibers is used in a five-axis computerized
numerically controlled machine tool to evaluate the tool’s ability to polish nonplanar BK7 components. The five-
axis system has an inline slurry feed system which is found to produce higher material removal rates than the
nonrecirculatory slurry bath configuration used in earlier polishing tests. Polishing results obtained on planar and
spherical surfaces in the five-axis system show close agreement with that predicted via convolution. A finite
element model of the fiber’s interaction with a concave surface shows that the calculated local pressure dis-
tribution reflects that observed experimentally, thus further supporting the predictable behavior of fiber-based
tools. © 2019 Society of Photo-Optical Instrumentation Engineers (SPIE) [DOI: 10.1117/1.OE.58.9.092610]
Keywords: polishing; spherical; determinism.
Paper 190087SS received Jan. 20, 2019; accepted for publication Apr. 11, 2019; published online May 3, 2019.

1 Introduction baseline testing for subsequent comparison with results

Previous publications by the group introduced the use of
fiber-based polishing tools1 in the polishing of optical
components. There are two main motivations for using
fiber-based tooling in polishing applications: first, the global
compliance (length scale > 5 mm) of individual fibers ena-
bles them to accommodate varying radii of curvature (ROC)
as found on aspheres and freeforms,2 and second, the fibers
are sufficiently stiff on the length scale of midspatial fre-
quency (MSF) features (length scale < 2 mm)3 so as to pro-
mote material removal (MR) from the higher regions of
the MSF features thus reducing their amplitude. The earlier
publications explained the tool–workpiece interactions influ-
encing the material removal rate (MRR),4 demonstrated
the stability of the tool,5 its interactions with the workpiece
edge,5 and its ability to reduce MSF errors on either BK7
glass or germanium.5 In this paper, the application of the
tooling in a five-axis system on spherical components is dis-
cussed. Factors that increase the tool’s MRR and reduce the
size of its tool’s footprint are also detailed.
2 Equipment and Experimental Setup
2.1 CNC Machining Centers
Two different setups were used to undertake the experiments
detailed in this paper: (1) a three-axis Haas computerized
numerically controlled (CNC) machine tool and (2) a five-
axis OptiPro Triumph system. The Haas CNC center has
a travel range of 762 mm × 305 mm × 406 mm in the XYZ
axes, respectively. A slurry bath was fixed to the table of the
machine with a total area of 275 mm × 260 mm. The sam-
ples were adhered to the surface of the slurry bath using
Loctite® Super Glue [see Fig. 1(b)]. This system was used
for evaluation of a tool with a smaller MR footprint, and for
obtained on the five-axis system. The five-axis Triumph
machine shown in Fig. 1(c) was used to conduct the first tests
using a fiber-based tool on spherical components. The five-
axis system has a travel range of 468 mm × 210 mm ×
200 mm in the XYZ axes and −90 deg to 90 deg on the
B axis of the machine. The workpiece was adhered to the
XY axis using optical polishing pitch. The slurry was deliv-
ered via a channel drilled unto the centerline of the tool, as
well as external delivery hoses with a feed rate of 5 L∕ min.
On both test setups, UltraSol® Optiq, a ceria-based slurry
with a mean particle size of ∼0.4 μm, was used.
2.2 Nylon 6/6 Fiber Tool
Figure 2(a) shows the tooling configuration used in the
majority of the tests described in this paper. While more
details can be found in previously published papers,4–6 a brief
summary of the tool’s design criteria and its tool influence
function (TIF) are summarized here. A simple strategy to
reduce the tooling’s foot print is also provided.
Twelve fibers, made from nylon 6/6 having a diameter of
1.6 mm and lengths of the order of 25 mm, were arranged
circumferentially in the tool and parallel with the tool’s axis
of rotation.4 While the configuration of the fibers in these
polishing tools has not yet been optimized, the material
choice and fiber arrangement should be such as to (1) facili-
tate fiber-workpiece contact lengths of several mm, (2) ensure
that a sufficiently high bending moment exists, induced by
their bending when contacting the surface, so as to impart
an applied load on the workpiece, and (3) ensure all fibers
maintain consistent contact with the workpiece surface under
rotational and translational conditions. Figure 2(b) shows the
tooling engaged with the workpiece, while Fig. 2(c) shows
a cross section through a TIF obtained on a planar BK7
sample after a 10-min spot test in the slurry bath polishing

*Address all correspondence to Brigid Mullany, E-mail: bamullan@uncc.edu 0091-3286/2019/$28.00 © 2019 SPIE

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 Shahinian and Mullany: Polishing spherical BK7 workpieces with fiber-based tools

Fig. 1 (a) Haas TM-1, (b) inset detail of Haas, (c) OptiPro Triumph, and (d) nylon 6/6 tool.

Fig. 2 (a) Basic tool configuration, (b) tool in contact with the workpiece, and (c) cross section of the
MR profile.

Fig. 3 Modified nylon 6/6 tool for smaller foot print: (a) physical tool and (b) MR profile during spot test.

configuration. The fluctuation in the v-shape profile at a
distance between ∼
16 and 20 mm is not fully understood
but could be attributed to inconsistencies in the early tool
fabrication methods, or particle agglomeration in the non-
circulatory slurry bath system.
While the fiber workpiece contact length was ∼10 mm,
the tooling configuration was such that the stationary MR
footprint was an annular ring with outer and inner diameters
of 45 and 35 mm, respectively [see Fig. 2(c)]. To reduce the
size of this footprint, a simple solution is proposed whereby
the fibers are not parallel to the rotation axis but inclined
inward [Fig. 3(a)] so that when the tool engages with the
workpiece the fibers are directed toward the centerline of the
tool, resulting in a smaller foot print. The results of a single
spot test demonstrating its feasibility are detailed in Fig. 3(b).
As noted at the start of this section, the tooling configuration
has not yet been optimized and plentiful opportunities exist
to further tailor its performance.
3 Factors Affecting the Material Removal Rate
from BK7 Glass
It was demonstrated that the tools remove material from the
regions where the fibers were in contact with the workpiece
or sufficiently close to the workpiece so as to entrain abrasive

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 Shahinian and Mullany: Polishing spherical BK7 workpieces with fiber-based tools

particles along their leading edge as they sweep over the
workpiece surface.4 Limited testing indicates that fiber-based
tools are Prestonian in nature with the MR increasing with
higher applied loads and rotational speeds. The relationship
between the pressure and the MR was also supported by the
fact that the experimentally measured MR profile shape
reflects the finite element-based prediction of the pressure
distribution induced by fiber contacting the workpiece sur-
face.4 It was also observed that the MR is linearly propor-
tional to the number of fibers on the tool, i.e., more fibers
provide a higher MR.
In this section, the impact of the slurry delivery method on
the MR is examined by comparing the MR profiles obtained
using the nonrecirculatory and recirculatory slurry systems.
The predictability of the fiber-based tool while undertaking a
spiral-raster path on a planar part on the five-axis system is
also explored.
3.1 Material Removal in a Slurry Bath Configuration
Initial tests undertaken in the nonrecirculatory slurry bath
configuration on the Haas system reported consistent but
relatively modest MRRs. For example, the MR profile illus-
trated in Fig. 4(a) was obtained after 10 min of polishing in a
stationary position at 100 rpm (no tool translation) using
UltraSol® Optiq slurry on a planar BK7 glass workpiece.
During the 10-min polishing tests, some settling of particles
was observed close to the tool, suggesting that the stationary
slurry bath does not provide sufficient slurry agitation to pro-
mote the introduction of fresh abrasives to the polishing
region.
hence remaining profile) of which is dependent on the local
pressure applied by the bent fiber.7 While the model found
good agreement between predicted (Sq ¼ 0.76 nm) and
actual (Sq ¼ 0.94 nm) surface finishes, it also supports the
belief that higher MRRs are achievable when more abrasives
are present along the fiber’s leading edge.
3.2.2 Deterministic polishing on planar surface
Previous work5 detailed that the nylon 6/6 TIF remains rea-
sonably consistent in a simple trace–retrace translational
motion while in the slurry bath configuration. The TIF sta-
bility enabled the prediction of the tool’s polishing outcomes
by convolving the TIF and the tool’s dwell time matrix. To
verify the stability of the TIF of the nylon 6/6 tool in the
inline slurry feed system, a planar BK7 sample was polished
with the tool translating over the workpiece in a spiral path
(see Fig. 5). To preclude any workpiece edge–fiber inter-
actions, the tool was translated over only 40% of the optic’s
aperture. Due to the MR mechanism of the nylon 6/6 tool and
the Prestonian nature of the MR, the instantaneous absolute
velocity of each abrasive particle relative to the reference
frame attached to the workpiece should be calculated.
Both the tool and workpiece had constant rotational speeds
around their respective shanks, as the tool was translated
from the center of the optic to the edge, and vice versa.
To calculate the absolute velocity of the fiber in the coordi-
nate system attached to the workpiece, the velocity of the
fiber relative to the workpiece, i.e., Vfiber∕workpiece , was added
to the velocity of the workpiece, i.e., Vworkpiece , using the
vectoral relation shown in Fig. 5. The Vfiber∕workpiece is the

3.2 Material Removal in with a Recirculatory Slurry

Delivery System
3.2.1 Spot test on planar surface
The polishing test described in the previous section was
repeated in the Triumph machine which has an inline slurry
feed system, delivering slurry to the tool workpiece region at
a rate of 5 L∕ min. As shown in Fig. 4(b), the MRR achiev-
able with this system was significantly higher (990%) than
possible in the slurry bath. The increased MRR is believed
to be related to the continuous introduction of fresh abrasives
to the fiber leading edges and to the negligible chance of
particles settling out of the slurry during the testing period.
This result is consistent with the results from a model gen-
erated to predict the expected surface finish.6 The model
assumes that each particle along the fiber’s leading edge Fig. 5 Nylon 6/6 tool kinematics during spiral polishing of concave
removes a minuscule volume of material, the volume (and and planar BK7 samples.

Fig. 4 MR profile obtained on BK7 glass with (a) a slurry bath configuration and (b) the inline feed con-
figuration. The linear MR profiles extracted are from Fizeau interferograms of the polished BK7 samples.

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 Shahinian and Mullany: Polishing spherical BK7 workpieces with fiber-based tools
Fig. 6 (a) Three-dimensional polishing MR map predicted by convolution and linear trace across the
dashed line and (b) Fizeau interferogram of experimentally polished planar BK7 glass.
product of the position of the fiber relative to the shank of
the tool (rt ) and the tool’s angular velocity (ωt ), whereas
Vworkpiece is the product of the workpiece’s angular velocity
(ωw ) and the position of the fiber relative to the center of
rotation of the workpiece (rw ). Based on the calculated abso-
lute velocity of the fiber, the convolution TIF is adjusted
linearly.
MR predictions and an actual experiment were con-
ducted with the following conditions. The workpiece was
a ∅75-mm planar BK7 glass with initial flatness of λ∕4
(λ ¼ 632.8 nm). The tool spindle and the workpiece spindle
were rotated at 100 and 356 rpm, respectively. The tool’s
spiral stepover was 0.5 mm and the total polishing time was
5 min. The tool dwell time matrix was generated, and the
tool’s measured TIF (obtained from a spot test with no tool
translation in the inline slurry system) was processed in the
convolution algorithm to predict the final form of the work
piece after testing under the spiral translation conditions.
Figure 6(a) shows the three-dimensional map calculated
via convolution, while Fig. 6(b) shows the actual Fizeau
interferogram of the planar BK7 glass post the spiral polish-
ing. The MR profiles show a good agreement, and the total
volume of MR obtained experimentally was 7% higher than
that predicted by convolution. The main reason behind the
increase in MRR during the translational test is speculated
to be a higher level of slurry circulation and particle engage-
ment as a result of the better mixing conditions due to the
addition of the tool’s translation over the surface which is
absent in the spot test used to generate the TIF.
4 Polishing Spherical Samples
To evaluate the fiber-based tool’s ability to polish nonplanar
samples, both finite element modeling (FEM) and polishing
tests were conducted on a spherical BK7 sample having an
aperture of 80 mm and an ROC of 75 mm.
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4.1 Finite Element Modeling of the Fiber Workpiece
Interaction
An FEM was generated in ABAQUS® to gain insights into
the expected MR profile generated by the fibers in contact
with the spherical workpiece. For comparison purposes, the
previously obtained FEM results on the planar example are
also included.4 To curtail simulation time as much as pos-
sible, only 1∕8 of an arc of the sample was created. The fiber
was halved along its symmetry line. Totals of 256,834 nodes
and 166,952 elements were created in the process of meshing
the part. The C3D10M elements were used. More details of
the FEM approach can be found in Refs. 4 and 5. Figure 7(a)
shows the created FEM geometry and the calculated contact
pressure distribution of the fiber on the workpiece, whereas
Fig. 7(b) depicts the extracted pressure profile across the
centerline of the contact pressure distribution. The abrupt
change in the pressure profile near the local minimum is
most likely due to the extreme fiber deformation and the
existence of an inflection point in the fiber as a consequence
of the large deformations.
The width of the pressure profile on the concave surface
was narrower than that on a planar surface. The fiber contact
widths predicted by the FEM on the planar and concave sur-
face were 3.754 and 2.8 mm, respectively. The width of the
pressure profiles (CPRESS quantity in ABAQUS) extracted
from the FEM underpredicts the experimentally obtained
effective polishing widths on both planar (6.18 mm) and
spherical (5.05 mm) cases (see Fig. 8 in the next section).
Based on the proposed MR mechanism, whereby the effec-
tive polishing width is not just the region where the fiber
directly contacts the workpiece, but the length of fiber that
can entrain particles along its leading edge, an additional
ABAQUS parameter (COPEN) which evaluates the gap be-
tween the fiber and the workpiece was used. The fiber-work-
piece effective contact length where the COPEN parameter
was less than the slurry abrasive particle size (i.e., 400 nm)
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 Shahinian and Mullany: Polishing spherical BK7 workpieces with fiber-based tools

Fig. 7 FEM of fiber-concave workpiece interaction: (a) overall model geometry and the pressure distri-
bution of the fiber on the workpiece and (b) graphical depiction of the pressure exerted by the fiber on
the workpiece, i.e., the pressure along the dashed line in (a).

Fig. 8 Spot profile of the nylon 6/6 tool: (a) concave surface and (b) planar surface. The effective contact
width of the nylon 6/6 on the surfaces is 5.05 and 6.18 mm, respectively.

was calculated for the planar and spherical surfaces. The
newly predicted polishing widths using COPEN were 6.8
and 5.5 mm. The better agreement of these numbers with
experimental polishing widths further adds credibility to the
proposed MR mechanism of the nylon 6/6 tool.
The validity of the FEM also introduces the opportunity
of using the model in extending the application of the nylon
6/6 tool to parts with varying ROC’s. Basically, the evolution
of the pressure distribution of each fiber as a function of the
local ROC can be accommodated in the dwell time matrix,
thus achieving smallest possible surface form errors.
4.2 Material Removal on the Spherical Sample
To determine if convolution based final form predictions
on a spherical surface is feasible, the procedure detailed
in Sec. 3.2.2. was repeated. A spot test was first performed
on the spherical workpiece to determine its TIF (see
Sec. 4.2.1). This was then combined with the calculated
dwell time matrix for a spiral translation pattern, and the
predicted final form was calculated (see Sec. 4.2.2).
4.2.1 Spot test result on the spherical sample
A 10-min spot test was conducted using the UltraSol® Optiq
slurry, with a tool rotational speed of 100 rpm. The work-
piece sample was not rotated during the test nor was the
tooling translated. Figure 8(a) shows the linear cross-section
profile of the measured MR interferogram. For comparison
sake, the MR profile obtained on a planar BK7 sample under
similar conditions is included in Fig. 8(b). Reasonable
agreement was found between the FEM predictions and that
obtained experimentally for both surfaces. Additionally, in
the case of the spherical sample, the abrupt change in the
MR profile near the local minimum as predicted by the
FEM model was observed in the actual MR profile.
4.2.2 Deterministic polishing on spherical sample
Taking the TIF [Fig. 8(a)] and the calculated tool dwell
times, the form of the polished workpiece was predicted
as shown in Fig. 9(a). Note that the power was removed from
the predicted profile. This was the expected result after
10 min of polishing. Figure 9(b) depicts the actual measured
workpiece surface (the spherical component of the measure-
ment was again removed). The total volume of experimental
MR was 3% more than that predicted by convolution. The
measured form error of the sample from that predicted by
convolution, as a result of the polishing, was λ∕5 PV and
λ∕24 RMS. As reported in Ref. 8, form errors of the same
order of magnitude can be achieved with first iteration of
commercial magnetorheological finishing (MRF) processes.
Form errors of the order of λ∕100 PV and λ∕200 RMS are
reported to be feasible with appropriate number of iterations
using the MRF system. In case of the nylon 6/6, an expo-
nential drop in the load applied by the tool over time can
be expected due to plastic creep of the nylon fibers
themselves.4,9 Published literature is available indicating the
creep of nylon 6/6 over time,9,10 and its effect on the polish-
ing load has been reported in Ref. 4. From experimental
observations, it has been seen that the nylon 6/6 fiber is

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 Shahinian and Mullany: Polishing spherical BK7 workpieces with fiber-based tools
Fig. 9 (a) Three-dimensional polishing MR map predicted by convolution and linear trace across the
dashed line and (b) Fizeau interferogram of experimentally polished concave BK7.
almost completely restored to its original shape post the
polishing and its disengagement with the workpiece. Re-
engaging the tool resulted in the same exponential load drop
as per the previous test. These observations are consistent
with that reported in Ref. 11. These loading variations at
each test could be the main culprit in inducing the form
errors. The polishing load drop specially is of great magni-
tude (over 30%) in the first 30 min of the tool engagement.4
That said, with proper compensation in the tool loading, such
errors can be minimized. Moreover, the error could be further
compensated by adjusting the dwell time matrix and more
iterations in polishing the workpiece.
5 Conclusions
In this paper, the successful integration of fiber-based tools
into commercial three-axis and five-axis polishing centers
was demonstrated. The testing in the two centers differed
in their delivery of the slurry to the polishing zone, i.e.,
submerged (three-axis) versus inline (five-axis), and in their
kinematic options. In both cases, the nylon 6/6 tool demon-
strated deterministic MR from BK7 glass samples. The inline
feed system provided additional insights on the physics of
MR of the nylon 6/6 tool whereby the increase in MRR
achievable with the inline system was concluded to be a con-
sequence of more abrasive particles being introduced to the
fiber’s leading edges during polishing.
Experimental data showcased one of the advantages of
fiber-based tools, i.e., the use of one tool for different surface
geometries. The same nylon 6/6 tool was used for polishing
both planar and spherical surfaces. In addition, the MR pro-
file shapes obtained after polishing were in agreement with
the FEM predictions. The good agreement between experi-
mental and FEM implies the same modeling approach can be
used in predicting the MR of the tool on different surface
geometries, i.e., aspheres and freeforms.
Polishing planar and spherical samples revealed that the
nylon 6/6 tool induces form errors of the order of λ∕5 PV.
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While this amount of error is not sufficient for the final figure
of an optic designed for the visible domain, it is believed that
compensation for the fiber’s creep over time in the tool’s
dwell time matrix can significantly improve its deterministic
performance.
Acknowledgments
This research was supported by the NSF I/UCRC Center
for Freeform Optics (Nos. IIP-1338877 and IIP-1338898)
and partially supported by NSF’s IRD program. We also
thank the OptiPro Systems for providing the onsite testing
on the Triumph machine and Eminess Technologies for
providing the UltraSol® Optiq polishing slurry.
References
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 Shahinian and Mullany: Polishing spherical BK7 workpieces with fiber-based tools

Hossein Shahinian received his PhD from University of North
Carolina at Charlotte in 2018. Upon graduation, he joined Micro-
LAM, Inc. in Michigan, United States, where he works in the research
and development division as process engineer. His research
areas are mainly focused on design and development of opto-
mechanical systems for ultraprecision laser assisted machining
processes of brittle and hard materials. He is also an active member
of SPIE.
Brigid Mullany received her doctorate from University College
Dublin, Ireland. After a Marie Curie postdoctoral position at Carl
Zeiss in Germany, she joined the University of North Carolina at
Charlotte, where she is now a professor in mechanical engineering.
Her research areas include surface finishing and metrology. She is an
associate member in the International Academy for Production
Engineering (CIRP) and is currently on rotation as a program director
in the NSF Advanced Manufacturing program.

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