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Surface Generation for Magic-Mirror by End-Milling and Magnetic Polishing with Digitally Functioned CNC Machining Center

This paper describes fabrication of a magic-mirror with an extremely small concavo-convex surface, which is invisible to the naked eye. The magic-mirror was manufactured by end-milling with a machining center on the rear of the workpiece after polishing. Incident light was radiated to the mirror surface and the reflected light was projected on a screen. The tool pass by CNC programming show up as image of magic-mirror on the screen. Analysis of the image on the screen indicated completion rate of magic-mirror surface generation. As some experimental result, the integrated magic-mirror production process on the machining center could be achieved by a novel application of on-machine magnetic abrasive finishing and ball end-milling. Moreover, it was found to possible to fabricate a magic-mirror with satiny and continuous-curvature corrugated surface.