Because of the K2K Sci-Fi detector geometry, we had to assemble and glue the fiber layers into bundles of size suitable for the image intensifiers on the experimental hall floor, after the detector was completely assembled. Thus it was not possible to trim and polish the scintillating fiber bundles in a machine shop; we needed a portable machine tool compact enough to fit into the very limited space available.
For this purpose, UW provided a custom made fiber bundle polisher -- essentially, a special-purpose milling machine with diamond bits and pre-programmable action, sufficiently idiot-proof to be operated by physicists. The machine was designed by Carl Lindenmeyer, and built by PM Manufacturing, of Yorkville, IL.
John Roze, machine shop supervisor at UW, went to KEK to supervise preparations and train physicists in November, 1998, and polishing operations were completed in early January, 1999. For the UW group, J. Wilkes was responsible for organizing the polishing operation, and H. Berns and S. Boyd assisted with preparations and operations.
Due to schedule delays, J. Roze had to leave KEK before polishing began, so At. Suzuki (Kobe U) actually did most of the machining. S. Matsuno (Hawaii) designed the bundling scheme, while M. Sakuda (KEK) was responsible for the overall design and assembly of the sci-fi detector.
J. Roze with polishing machine as set up for vertical layers.
J. Roze training At. Suzuki in machine operation.
Polisher in action (cutting a transparent acrylic cylinder).
Polisher set up for work (bundles have not yet been assembled).
View of polisher setup on detector platform.
J. Wilkes with finished horizontal-layer bundles.
J. Wilkes and M. Sakuda inspecting finished vertical-layer bundles.
Polished bundle, with wavelength shifter activated by daylight.
Inspection microscope view of polished fibers.
More photos by Hans Berns and J. Wilkes.