Investigation into the regulation of diamond magnetic composite abrasives for polishing of sapphire domes

Abstract Diamond magnetic composite abrasives were utilized to achieve precision polishing of sapphire domes. The synthesized diamond particles were uniformly dispersed and partially embedded within the iron powder matrix, and a magnetic abrasive regulation model was developed within the tool to define its optimal rotational speed range. This study systematically examined the influence of tool rotational speed, polishing duration, slurry concentration, and applied pressure on the surface roughness and material removal rate of sapphire domes and identified the optimal combination of processing parameters for each factor. After polishing, the sapphire dome demonstrated an infrared transmittance as high as 85%. During the polishing of sapphire using diamond magnetic abrasives, the abrasive particles remain flexibly confined between the workpiece and tool, continually engaging the surface with renewed cutting edges throughout the process. This intrinsic self-dressing behavior promotes sustained micro-cutting and contributes to the attainment of superior surface quality. After polishing, the diamond particles in the composite abrasives exhibited no significant wear and only minor particle detachment was observed.