Micro/meso ultra precision grinding of fibre optic connectors

The present paper reports on the development of a micro/meso grinding technology using inclined resin bond diamond cup wheels for machining spherical end faces of fibre optic connectors. The ground spherical end faces obtained using the wheel of grit size of 4 μm have an average roughness (R_a) value of 7 nm in the fibre area and a profile error of below 0.4 μm. The corresponding average return and insertion losses are 55 and 0.1 dB, respectively. The results are competitive to those obtained from the polishing process that is currently used in industries. Furthermore, this study has revealed the relationships between the ground surface quality characterized by roughness and profile accuracy and the optic performance evaluated by insertion and return losses.