PJ-D3 Ultra Precision Polishing Fixture Manual
Contents
1. 11 Shaft 1 12 Load spring 1 13 Up load adjustment ring 1 14 Vacuum seal sleeve 1 15 Scale plate 1 16 Socket head screw 3 17 Socket head screw 1 18 Socket head screw 2 19 Vacuum seal ring 1 20 Socket head screw 6 21 Socket head screw 6 22 Set screw 24 23 Base plate 1 24 Chuck plate 1 29 O ring 1 26 O ring 1 27 Seal plug 1 28 Socket head screw 4 29 Locking nut 1 30 Screw 1 31 Balance weight 2 32 Socket head screw 3 33 Angular adjustment screw 3 34 Stock removal presetting ring 1 35 Long pillar 2 36 Supporting ring 1 37 Supporting screw 4 38 Plastic washer 1 39 Vacuum tube 1 HI 3 Structural description see Fig 1 The shaft 11 is fixed on the base plate 23 by four socket head screws 28 tightly The vacuum seal sleeve 14 is fixed tightly on the top of the shaft 11 by two socket head screws 18 This shaft combination 11 23 14 and all parts attached to these three parts are considered as a whole named movable assembly The spacer pillar 2 is fixed on the drive ring 1 by the male end of the male female screw 3 and the female end is matched with the socket head screw 32 that is used to fix the body base plate 4 on the spacer pillar 2 The main sleeve located inside the covering sleeve 3 not shown in Figure 1 is fixed on the top of the body base plate 4 by six socket head screws 20 This main sleeve combination including 1 2 4 8 and all the parts connected are name2. angular adjustment screws 33 on the body base plate 4 are shown in Fig 2 The pitch of these screws is 0 5mm The adjustment processes of polishing the wedge suppose the wedge angle is show as follows 2 Fig 2 1 Polish the fixture without specimen until the entire surface of the chuck plate 24 is polished 2 Screw in the three angular adjustment screws 33 until they contact the top surface of the spacer pillars 2 3 Slightly unscrew the three socket head screws 32 and then turn the screw 33 at position C See Fig 2 to a degree in clockwise where a 0 36650 For example if the required wedge angle is 30 the angle a should be 10 99 4 Tighten the three socket head screws 32 with a torque screw driver that will help to tighten these three screws with same torque 5 Turn the fixture upside down and place the polished surface of the specimen Assume one of the specimen surface has already been polished on the chuck plate 24 with the ridge of the wedge in AB direction See Fig 2 6 Remove the seal plug 27 if it if covered by the specimen Block the screw holes that are not covered by the specimen on the chuck plate 24 by set screws 22 7 Insert the greased vacuum tube 39 with the washer 38 into the fixture and connect the vacuum tube 39 to the vacuum pump 8 Turn on the vacuum pump and polish the second surface of the specimen on the polishing plate of the polishin
3. top surface of the base plate 23 Then tighten the two screws 6 Read the number shown on the dial indicator This number will not change until the ring 13 is turned in and contacts the load spring 12 The user can choose either method at his her convenience 5 The maximum polishing load of the specimens is 2075 G gram This load can be reduced by adjusting the down load adjustment ring 9 Once the ring 9 Once the ring 9 is turned in counter clockwise direction the load spring 12 is compressed Therefore it partially balances the weight of the movable assembly and reduces the load The load can be calculated from the scales on the upper end of the down load adjustment ring 9 Each division of the scale corresponds 5 5 gram The rotated number of divisions N can be read fro the scale against the index line engraved on the up load adjustment ring 13 There are two sets of index lines One is a single line and the other consists of double lines The two sets are separately distributed You may choose either set for your convenience According to the number of N the polishing load W can be calculated as W 2075 G 5 5N gram You may calculate the number of N from the preferred polishing load W as N 2075 G W 5 5 6 Before processing turn in the screw 17 until it contacts the top surface of the up load adjustment ring 13 to prevent the ring 13 rotating by accident during processing 4 Controlling the stock rem
4. A User s Manual For the Operation and Maintenance Of the PJ D3 Ultra Precision Polishing Fixture Surface Technologies Incorporated A User s Manual For the Operation and Maintenance Of the PJ D3 Ultra Precision Polishing Fixture Contents Page I Introduction 3 II Specification and the structure 3 1 Specifications 2 The structure diagram and components 3 Structural description III Operations 6 1 Mounting specimens and polishing parallel surfaces 2 Polishing wedge specimens 3 Adjusting the polishing load 4 Controlling the stock removal IV Maintenance 10 Surface Technologies Incorporated I Introduction The PJ D3 ultra precision lapping polishing fixture is used to hold flat specimens of widely varied geometries to be precisely lapped polished on MTI Unipol 1202 or Unipol 1502 machine or similar machines The key component of this fixture is its shaft system The accuracy of a fixture is determined by the size of the clearance between the shaft and the sleeve Since the large clearance causes the shaft rocking in processing and results in bad flatness and parallelism of the surfaces to be polished The PJ D3 fixture uses a patented shaft system that is very accurate and the clearance between the shaft and the sleeve can re renovated after parts are wore out With this patented shaft system this fixture can precisely control the orientation of the surface to be polished and achieve an excellent parallelism or accur
5. arallelism requirement the chuck plate 24 and the vacuum system must be used The process proceeds as follows 1 Polish the surface of the chuck plate 24 without specimen until the entire surface has been polished and then the surface is co planar with the surface of the drive ring 1 2 Let the fixture upside down and place the specimen s on the surface of chuck plate 24 3 Remove the seal plug 27 if it is covered by the specimen Using the set screws 22 to block the screw holes that are not covered by the specimen s 4 Paste the vacuum tube 39 with some vacuum grease and insert it with washer 38 into the fixture then connect vacuum tube 39 with the vacuum pump and turn on the vacuum pump 5 Turn the fixture down so the specimen is facing downward Then place the fixture on the polishing plate of the polishing machine 6 Polish the first surface of the specimen until the entire surface is polished 7 Turn off the vacuum pump 8 Clean the specimen and the chuck plate 24 before turning over the specimen and then polish the second surface of the specimen according to the previous steps A precise parallelism of the specimen will be achieved 2 Polishing wedge specimens Generally the three angular adjustment screws 33 are not screwed into the body base plate 4 and the body base plate 4 is tightly pressed on the three spacer pillar 2 by the three socket head screw 32 The locations of the three
6. ate wedge plates Features of this fixture also include adjustment of polishing load stock removal indicating stock removal presetting and vacuum chuck vacuum motor is not included The PJ D3 fixture is constructed throughout with stainless steel II Specifications and the structure 1 Specifications Net weight 5 9Kg 13 lbs Height 196mm 7 72 Overall diameter 152mm 6 Angular adjustment range 3 Range of loading 0 3600g Maximum specimen diameter 105mm 40 Maximum specimen thickness 37mm 1 45 Specimen parallelism achievable 2 of arc Minimum achievable thickness 2 5um Depending on the material of the specimen and process condition Subject to change without notice 2 The structure diagram and components The structure diagram of PJ D3 is given in Figure 1 The major components are listed in Table 1 SINAN A BEEN y Lia Lr AEN theres a Vi i n i mi CS SAAN 77 an i QNT EME ae ll do ane a See yi Ji Vine vil sit I Saf IT LLI me Nidi a ee SETA I a if Fig 1 Table 1 Part number Name of the part Quantity 1 Drive ring l 2 Spacer pillar 3 3 Male female screw 3 4 Body base plate 1 5 Dial indicator pedestal 1 6 Round head screw 2 7 Locking nut 1 8 Covering sleeve 1 9 Down load adjustment ring 1 10 Spring seat 1
7. d stationary assembly The exceptionally fine precision fit of the shaft 11 in the main sleeve allows the shaft to slide up and down freely without causing rocking motion of the base plate 23 on which the chuck plate 24 as well as the specimens is mounted In lapping polishing process the stationary assembly is always sitting on the lapping polishing plate of the lapping polishing machine The drive ring 1 supports the fixture on the lapping polishing plate and contacts rollers on the drive arm of the machine to allow the fixture to rotate on the plate The movable assembly also sits on the plate and rotates with the stationary assembly synchronously but it also can move up and down freely relative to the stationary assembly as needed The specimens are held on the chuck plate 24 by the vacuum force or wax As the stock is removed the movable assembly as well as the polishing surface of the specimen will be perfectly in plane with the lapping plate The screw 30 is used to support the base plate 23 in any desired level while the fixture is in upside down position The base plate 23 faces up position This screw also can prevent the dial indicator if any from possible damage as the base plate 23 sliding down Do not let the screw 30 touch the base plate 23 during lapping polishing operation Operation see Fig 1 1 Mounting specimens and polishing parallel surfaces Ordinary specimens can be mounted on the s
8. e stock removal presetting ring 34 One division of the scale corresponds 0 01mm of stock removal After setting the stock removal amount lock the position of the stock removal presetting ring 34 by tightening one or all the three screws 16 IV Maintenance The PJ D3 fixture is precisely designed engineered and constructed throughout with stainless steel Under normal usage it will give you years of satisfactory service What the user needs to do are cleaning the fixture s surfaces with soft tissues or cloths after every use and periodically lubricating the shaft system with silicon oil If the chuck plate 24 has been dismounted from the base plate 23 or a new chuck plate is used the chuck face should be lapped to keep it flat and parallel state Once the fixture is damaged for example dropped down by accident it should be returned to factory for repairing After years of use the clearance between the shaft and the sleeve will increase due to wear The flatness and parallelism of the products can no longer be controlled In this case the fixture should be returned to factory and be renovated Please do not loosen screws 20 28 and 3 Otherwise the parallelism of the fixture cannot be restored D WP DATA PRODUCT INFORMATION PJ D3 Ultra Precision Polishing Fixture manual doc 10
9. g machine As the entire surface is polished the required wedge angle is achieved 3 Adjusting the polishing load The polishing load on the specimen s is the total weight of the movable assembly This is the maximum load that can be reduced by the following steps 1 Mount the specimen on the fixture as described above 2 Put the fixture on a flat surface such that the drive ring 1 and the specimen contact the flat surface 3 Turn the down load adjustment ring 9 clockwise viewing from the top to the lowest position 4 Turn the up load adjustment ring 13 clockwise viewing from the top until it contacts the load spring 12 There are many small holes on the ring 13 those are used to turn the ring up or down with the tip of a ball pen or a fine wooden stick There are two methods to identify whether the ring 13 is contacting the load spring 12 a The first method Tie one of the screws 16 or 17 with a string and hang the string under a spring balance In case the ring 13 is not contacting the load spring 12 the reading of the spring balance should equal to 2075 G gram where G is the weight of the specimen to be polished and 2075 gram is the weight of the movable assembly Once the ring 13 contacts the load spring 12 the reading of the spring balance will start to decrease b The second method Insert a dial indicator into the dial indicator pedestal 95 until the probe of the indicator contacts the
10. oval amount One way to control the stock removal is using a dial indicator Insert the dial indicator into the dial indicator pedestal 5 until the probe contacts the top surface of the base plate 23 and then tighten the round head screws 6 As the fixture sits on a flat surface the number read from the dial indicator presents the stock removal is zero now You also can set this number to zero As the specimen is being polished the number shown on the dial indicator is decreasing The difference between these two numbers is the amount of stock removal Pay attention to the changing of this number to control the stock removal To compensate the weight of the dial indicator on one side of the fixture two balance weights 31 should be installed before polishing In addition to a dial indicator for monitoring the lapping polishing process the PJ D3 fixture is equipped with a presetting stock removal device to prevent from over polishing After adjusting the polishing load turn the stock removal presetting ring 34 in clockwise direction until its bottom edge contacts the up edge of the down load adjustment ring 9 In this condition the movable assembly cannot drop down anymore It means that no stock will be removed in processing Then turn the stock removal presetting ring 34 in counter clockwise direction according to the preferred stock removal amount There is a scale on the surface of the scale plate 15 and an index line inside th
11. urface of base plate 23 directly sometimes for thick specimens or on the chuck plate 24 or on a special substrate with wax The chuck plate 24 is fixed on the base plate 23 by six socket head screws 21 Please note that these six screws are not spaced equally therefore there is only one position that the chuck plate 24 can fit the base plate 23 when they are assembled together Special substrates can be supplied by request For very thin specimens the chuck plate 24 and the vacuum system must be used According to the shape and size of the specimens screw in the set screws 22 into the holes that are not covered by the specimens Remove the seal plug 27 by pushing it with a pencil from the hole of shaft 11 if it is covered by the specimen Otherwise the seal plug 27 should always be plugged in to prevent foreign matters entering into the fixture Paste some vacuum grease on the vacuum tube 39 and slide the washer 38 on the vacuum tube 39 then insert them into the hole of the shaft 11 Connecting the vacuum tube 39 to a vacuum pump purchased separately and turn on the vacuum pump then the specimens to be polished will be sucked on the chuck plate 24 tightly Turn off the vacuum pump the specimens will be released automatically The vacuum tube 39 can freely rotate within the shaft 11 therefore the vacuum tube 39 will not rotate with the fixture during operation To polish a specimen with high precise p
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