Abstract: This paper presents the efforts made in the design, development and characterisation of a novel method of ice bonded abrasive polishing process. Mechanisms in various types of polishing machines were studied to identify the suitable configuration for developing an ice bonded abrasive polishing setup. Initially, a setup was developed with suitable kinematics for ice bonded abrasive polishing of flat surfaces. With the experience gained with the setup, suitable modifications in the setup were made to build a new setup for effective polishing of flat metallic surfaces. The developed setup is designed to prepare the polishing tool in situ with suitable temperature controller. The novelty of polishing setup lies in the method of preparation of cryogenic polishing tool by freezing the mixture of ultrafine abrasive particles with suitable cryogenic fluids. The characterisation of tool with optical image analysis and weight balance method showed the uniform distribution of abrasives in ice matrix. Finally, the effectiveness of ice bonded abrasive polishing process was demonstrated by analysing the finish produced on flat copper specimen.

Keywords:abrasive polishing, frozen tools, ice bonded polishing, self-replenishing, kinematics, temperature control, cryogenic tools, surface finish, surface quality, ice matrix, continuous replenishment, ultrafine abrasive particles