Surface & Cylindrical Grinding – Dongguan
Optical Projection Grinding is a high-precision grinding process with a spindle speed of up to 30,000 RPM, a maximum vertical stroke of 110mm, and a maximum vertical stroke speed of 400 cycles/mm. The tolerance is typically within 0.002mm, with surface roughness reaching Ra0.05μm.
Optical Grinding Technology Key Features and Advantages
Features
1. High Precision Processing Capability
Tolerances can be controlled within ±0.002mm for high-precision applications.
2. Optical Projection Assistance
The projection system magnifies and displays the workpiece profile on a screen, allowing the operator to visually compare it with the blueprint for precise and accurate processing.
3. Wide Range of Applicable Materials
Capable of processing high-hardness materials such as tungsten carbide, hard alloys, high-speed steel, as well as brittle materials like ceramics and semiconductors.
4. Automation and CNC Integration
Modern equipment is typically integrated with CNC systems, supporting programmed control of the grinding head's path, improving processing efficiency and consistency.
Advantages
1. Precision Processing of Complex Shapes
Especially suitable for processing complex contours such as arcs, narrow grooves, irregular holes, gears, punches, and mold components.
2. Excellent Surface Quality
Surface roughness of up to Ra0.05μm, reducing friction, wear, and stress concentration, enhancing wear resistance and lifespan.
3. Efficiency and Flexibility
Allows operators to precisely monitor the grinding process, ensuring that every step meets the required specifications.
4. High Flexibility
Suitable for mass production and highly adaptable for prototype and custom needs, efficiently handling different sizes, shapes, and materials.
Processing Steps for Optical Projection Grinding Parts
1. Workpiece Pre-treatment and Clamping
- • Cleaning: Use alcohol to remove oil, dust, and other impurities
- • Workpiece Clamping: Secure using vacuum suction cup, magnetic fixture, or precision mechanical clamp
- • Coordinate System Calibration: Align workpiece coordinate system with machine tool coordinate system
2. Optical Projection and Parameter Setup
- • Graphical Import: Project workpiece profile onto display screen (50-200x magnification)
- • Parameter Configuration: Set grinding spindle speed, feed rate, fine grinding, and grinding pressure
3. Rough Grinding
- • Material Removal: Use larger feed rate for rapid grinding to remove 80%-90% of total material
- • Precision Control: Surface roughness Ra1-2μm, flatness or contour errors ≤ 5μm
4. Fine Grinding
- • Precision Grinding: Switch to finer grain grinding wheels (diamond micro-powder wheels)
- • Real-Time Monitoring: Laser interferometers and optical encoders for feedback
5. Surface Polishing (Optional)
- • High-Precision Demand: Magnetorheological polishing, ion beam polishing, or CMP
- • Surface roughness down to Ra0.01μm, eliminating subsurface damage
6. Quality Inspection and Post-Treatment
- • Precision Verification: CMMs, height gauges, projectors to verify tolerances
- • Cleaning and Treatment: Clean with alcohol, ensure free of contaminants
Why Choose Our Optical Projection Grinding
1. Outstanding Processing Precision
Ultra-high precision grinding with excellent surface finish, ensuring highest quality standards.
2. Capability to Handle Complex Structures
Efficiently complete precision grinding of freeform surfaces, small apertures (≤0.1mm), and irregular contours.
3. Strict Quality Control
ISO 9001 certified, using Mitutoyo profile meters, Zeiss CMMs, and NIKON projectors for 100% inspection.
4. Efficient Delivery, Cost Control
48-hour delivery for small batch samples, 30% reduction in production cycle times for large orders.
5. Industry Expertise and Experience
Extensive experience in optical, semiconductor, precision machinery, and medical device fields.
6. One-Stop Service
From design and prototype sampling to mass production and after-sales maintenance, full-cycle support.
Application Fields
Optical projection grinding parts, with their high precision and ability to process complex structures, play a key role in several industries.
Optical and Optoelectronic Industry
- • Lenses, prisms, filters, optical windows
- • Fiber optic connector endfaces
- • Optical waveguide substrates
Semiconductor and Electronics
- • Silicon wafer and compound semiconductor grinding
- • IC packaging substrates and lead frames
- • Camera module lens brackets
Precision Machinery
- • Injection molds and stamping molds
- • Clock gears, gyroscope frames
- • Aerospace precision bearings
Medical and Biotechnology
- • Endoscope lens assemblies
- • Surgical instrument tips
- • Dental implant bases
New Energy and Environmental
- • Solar cell silicon wafer surfaces
- • Fuel cell flow channels
- • Photovoltaic module components
Consumer Electronics
- • Mobile phone frames and camera brackets
- • High-end watch cases
- • Automotive sensor housings
Optical Projection Grinding vs Traditional Grinding
| Feature | Optical Projection Grinding | Traditional Grinding |
|---|---|---|
| High Precision | High precision, Ra0.05μm | Micron-level precision |
| Complex Shape Machining | Aspheres, irregular contours | Regular shapes only (planes) |
| Machining Efficiency | Highly automated | Higher efficiency in mass production |
| Real-time Monitoring | Automatic compensation | Manual adjustment required |
| Suitable Materials | Tungsten steel, ceramics, silicon wafers, sapphire | Mainly metallic materials |
| Equipment Cost | High initial investment | Lower equipment costs |
| Application Scenarios | Optical lenses, semiconductors, aerospace | Mechanical parts, metal components |
FAQ
What types of workpieces can optical projection grinding process?
Optical projection grinding can process precision mold parts, cutting tools and tooling, optical components and precision parts, electronic and semiconductor components, aerospace and medical devices, tungsten carbide/ceramics, and more.
Models of Optical Projection Grinding Machines
WAIDA SPG-X, Rollomatic ShapeSmart® NP5, Okamoto ACC-12-24SA, Klingelnberg HÖFLER, Toyoda GL4i, SCHAUDT/MIKROSA KGM, Chevalier FSG-3A/4A
How to Choose the Right Optical Projection Grinding Service Provider?
Consider technical expertise and experience, equipment models and precision, quality control and certification, production capacity and delivery time, and after-sales service and technical support.