Spherical lapping method

A method of lapping a spherical head having a spherical surface disposed about a longitudinal axis, the method comprising the steps of:

• forming a central core having a top end defining a generally semi-spherical cavity,
• rotatably mounting the central core about a rotational axis,
• forming a polishing liner having a center portion and a peripheral portion,
• positioning the polishing liner in the generally semi-spherical cavity with the peripheral portion thereof extending over the top end of the central core,
• forming, an outer sleeve having an opening therein,
• mounting the outer sleeve over the central core to clamp the peripheral portion of the polishing liner in place while exposing the generally semi-spherical cavity through the opening, therein,
• manipulating a robotic arm to bring a spherical head into engagement with the polishing liner disposed in the generally semi-spherical cavity in the central core while it is spinning about the rotational axis, and
• manipulating the robotic arm to vary an angle between the longitudinal axis of the spherical head and the rotational axis of the central core during rotation of the spherical head about its longitudinal axis.

A method of lapping a spherical head having a spherical surface disposed about a longitudinal axis, the method comprising the steps of:

• rotatably mounting a lapping fixture having a top end defining a generally semi-spherical cavity about a rotational axis,
• securing a polishing liner in the generally semi-spherical cavity in the lapping fixture,
• applying a lapping compound to the polishing liner,
• manipulating a robotic arm to bring the spherical head into engagement with the polishing liner disposed in the generally semi-spherical cavity in the lapping fixture while it is spinning about the rotational axis,
• manipulating the robotic arm to vary an angle between the longitudinal axis of the spherical head and the rotational axis of the lapping fixture during rotation of the spherical head about its longitudinal axis, and
• rinsing the lapping compound from the spherical head.

A method of lapping a spherical bead having a spherical surface disposed about a longitudinal axis, the method comprising the steps of:

• forming a central core having a top end defining a cavity in the top wall thereof,
• rotatably mounting the central core about a rotational axis,
• forming a modular insert having a generally semi-spherical cavity and dimensioned for secure reception in the cavity in the top wall of the central core,
• positioning the modular insert in the cavity in the top wall of the central core,
• forming a polishing liner having a center portion and a peripheral portion,
• positioning the polishing liner in the generally semi-spherical cavity with the peripheral portion thereof overlying the top end of the central core,
• forming an outer sleeve having an opening therein,
• mounting the outer sleeve over the central core to clamp the polishing cloth in place while exposing the generally semi-spherical cavity through the opening therein,
• manipulating a robotic arm to pick up a spherical head,
• manipulating the robotic arm to bring the spherical head into engagement with the polishing liner disposed in the generally semi-spherical cavity in the modular insert while the central core/modular insert/polishing liner/outer sleeve assembly is spinning about the rotational axis, and
• manipulating the robotic arm to vary the angle between the longitudinal axis of the spherical head and the rotational axis of the central core during rotation of the spherical head about its longitudinal axis.

A method of lapping a spherical head having a spherical surface disposed about a longitudinal axis, the method comprising the steps of:

• forming a central core having a top end defining a cavity in the top wall thereof,
• rotatably mounting the central core about a rotational axis,
• forming a modular insert having a generally semi-spherical cavity and dimensioned for secure reception in the cavity in the top wall of the central core,
• positioning the modular insert in the cavity in the top wall of the central core,
• forming a generally daisy-shaped polishing cloth having a center portion and a peripheral portion comprising a plurality of arms extending away from the center portion,
• providing the generally daisy-shaped polishing cloth with an adhesive backing,
• positioning the polishing cloth in the generally semi-spherical cavity with the peripheral portion thereof overlying the top end of the central core, the adhesive backing ensuring good engagement between the mating surfaces of the polishing cloth and the semi-spherical cavity,
• forming an outer sleeve having an opening therein,
• mounting the outer sleeve over the central core to clamp the polishing cloth in place while exposing the generally semi-spherical cavity through the opening therein,
• applying a lapping compound to the polishing cloth,
• manipulating an arm of a robot to pick up a spherical head,
• manipulating the robotic arm to bring the spherical head into engagement with the polishing cloth disposed in the generally semi-spherical cavity in the modular insert while the central core/modular insert/polishing cloth/outer sleeve assembly is spinning about the rotational axis,
• manipulating the robotic arm to vary an angle between the longitudinal axis of the spherical head and the rotational axis of the central core during rotation of the spherical head about its longitudinal axis,
• moving the spherical head away from the central core, and
• rinsing the lapping compound from the spherical head.

A method of lapping a spherical head having a spherical surface disposed about a longitudinal axis, the method comprising the steps of:

• forming a central core having a top end defining a cavity in the top wall thereof,
• rotatably mounting a support spindle about a rotational axis,
• providing a motor for selectively causing rotation of the support spindle,
• resiliently mounting the central core on the support spindle for rotation therewith about the rotational axis,
• forming a modular insert having a generally semi-spherical cavity and dimensioned for secure reception in the cavity in the top wall of the central core,
• positioning the modular insert in the cavity in the top wall of the central core,
• forming a generally daisy-shaped polishing cloth having a center portion and a peripheral portion comprising a plurality of and extending away from the center portion,
• providing the generally daisy-shaped polishing cloth with an adhesive backing,
• positioning the polishing cloth in the generally semi-spherical cavity with the peripheral portion thereof overlying the top end of the central core, the adhesive backing ensuring good engagement between the polishing cloth and the semi-spherical cavity,
• forming an outer sleeve having an opening therein,
• mounting the outer sleeve over the central core to clamp the polishing cloth in place while exposing the generally semi-spherical cavity through the opening therein,
• spraying the polishing cloth with a wetting agent and diamond suspensions,
• manipulating an arm of a robot to pick up a spherical head,
• manipulating the robotic arm to bring the spherical head into engagement with the polishing cloth sprayed with a wetting agent and diamond suspensions and disposed in the generally semi-spherical cavity in the modular insert while the central core/modular insert/polishing cloth/outer sleeve assembly is spinning about the rotational axis,
• manipulating the robotic arm to vary an angle between the longitudinal axis of the spherical head and the rotational axis of the central core during rotation of the spherical head about its longitudinal axis,
• moving the spherical head away from the central core, and
• rinsing the spherical head.

A method of lapping a spherical head having a spherical surface disposed about a longitudinal axis, the method comprising the steps of:

• rotatably mounting first, second and third lapping fixtures about their respective rotational axes, first, second and third lapping fixtures defining first, second and third generally semi-spherical cavities,
• securing first, second and third polishing liners in first, second and third generally semi-spherical cavities in the lapping fixtures,
• applying a relatively coarse grit first lapping compound and a wetting agent, an intermediate grit second lapping compound and a wetting agent and a relatively fine grit third lapping compound and a wetting agent to the first, second and third polishing liners respectively,
• manipulating an arm of a robot to pick up a spherical head,
• manipulating the robotic arm to bring the spherical head into engagement with the first polishing liner disposed in the first lapping fixture while it is spinning about its rotational axis,
• manipulating the robotic arm to vary an angle between the longitudinal axis of the spherical head and the rotational axis of the first lapping fixture during forward and reverse rotations of the spherical head about its longitudinal axis through less than a complete revolution,
• manipulating the robotic arm to move the spherical head to a rinsing/air drying station to rinse the first lapping compound from the spherical head and air dry the spherical head,
• manipulating the robotic aim to bring the spherical head into engagement with the second polishing liner disposed in the second lapping fixture while it is spinning about its rotational axis,
• manipulating the robotic arm to vary the angle between the longitudinal axis of the spherical head and the rotational axis of the second lapping fixture during forward and reverse rotations of the spherical head about its longitudinal axis through less than a complete revolution,
• manipulating the robotic arm to move the spherical head to a rinsing/air drying station to rinse the second lapping compound from the spherical head and air dry the spherical head,
• manipulating the robotic arm to bring the spherical head into engagement with the third polishing liner disposed in the third lapping fixture while it is spinning about its rotational axis,
• manipulating the robotic arm to vary the angle between the longitudinal axis of the spherical head and the rotational axis of the third lapping fixture during forward and reverse rotations of the spherical head about its longitudinal axis through less than a complete revolution, and
• manipulating the robotic arm to move the spherical head to a rinsing/air drying station to rinse the third lapping compound from the spherical head and air dry the spherical head.