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Automatic Laser-based Geometry Capture for Finite Element Analysis of Weld Beads

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Published on: July 25, 2025

Ion beam figuring of high-slope surfaces based on figure error compensation algorithm.

Yifan Dai¹, Wenlin Liao, Lin Zhou

¹National University of Defense Technology, DeYa Road, Changsha, Hunan, China 410073.

|December 3, 2010

Summary

This study introduces a novel method for high-precision figuring of high-slope optics using a linear three-axis machine, enabling inclined ion beam incidence. The technique successfully reduced figure error on a fused silica sample in under 10 minutes.

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Published on: February 27, 2013

Area of Science:

Optical engineering
Precision manufacturing
Surface metrology

Background:

Deterministic figuring processes require stable removal functions and accurate dwell time solutions for convergence, especially for steep optics.
Conventional methods for steep optics utilize five-axis machines with perpendicular ion beam incidence.
Ion Beam Figuring (IBF) is a precision manufacturing technique sensitive to ion beam incidence angle.

Purpose of the Study:

To propose and validate a high-precision figuring method for high-slope optics using a linear three-axis machine.
To enable inclined ion beam incidence, deviating from traditional perpendicular incidence requirements.
To demonstrate effective figure error compensation for improved dwell time solutions.

Main Methods:

Analysis of removal function and normal removal rate variations with incidence angle in IBF.
Implementation of figure error compensation to mitigate effects of varying removal function and projection distortion.
Utilizing a linear three-axis machine with an incident ion beam parallel to the optical axis.

Main Results:

Simulations and experimental verification confirm the removal analysis for inclined incidence.
A fused silica sample with a 21.3 mm aperture and 16 mm radius of curvature was successfully figured.
The root-mean-square figure error was reduced from 13.13 nm to 5.86 nm in two iterations, taking approximately 9 minutes.

Conclusions:

The proposed method is effective for high-precision figuring of high-slope optical surfaces using a linear three-axis IBF machine.
Inclined ion beam incidence is feasible and advantageous for specific optical figuring applications.
The technique offers a potentially faster and more accessible approach to steep optic manufacturing.