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Convergent Polishing: A Simple, Rapid, Full Aperture Polishing Process of High Quality Optical Flats & Spheres
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Optimized pitch button blocking for polishing high-aspect-ratio optics.

Michael D Feit1, Richard P DesJardin, William A Steele

  • 1Lawrence Livermore National Laboratory, P.O. Box 808, Livermore, California 94551, USA. feit1@llnl.gov

Applied Optics
|December 25, 2012
PubMed
Summary

Pitch button blocking (PBB) optimizes convergent polishing for thin optics by maintaining workpiece stiffness. This process, refined through modeling and experiments, achieves sub-0.1 μm surface finishes on large optics.

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Area of Science:

  • Optics manufacturing
  • Precision engineering
  • Materials science

Background:

  • Convergent polishing of thin optics presents challenges in maintaining workpiece stiffness and block interface strength.
  • Existing methods may compromise optical integrity during high-precision polishing operations.

Purpose of the Study:

  • To optimize the pitch button blocking (PBB) process for noncompliant convergent polishing of thin workpieces.
  • To establish practical design criteria for PBB, including button parameters and spacing.
  • To validate the optimized PBB process on various workpiece sizes and aspect ratios.

Main Methods:

  • Experimental determination of optimal pitch button number, size, and spacing.
  • Theoretical analysis using a thermoelastic model to understand process mechanics.
  • Implementation and testing of the optimized PBB process on workpieces ranging from 100-265 mm.

Main Results:

  • Optimized design criteria for pitch button blocking were established.
  • The PBB process successfully maintained workpiece stiffness and block interface strength.
  • Sub-0.1 μm peak-to-valley heights were achieved on large workpieces (up to 45 aspect ratio).

Conclusions:

  • The optimized pitch button blocking process enables high-precision convergent polishing of thin optics.
  • PBB provides a robust method for achieving superior surface finishes on challenging optical components.
  • The established design criteria facilitate the practical application of PBB in advanced optics manufacturing.