Dual-rotor tool path generation and removal error analysis in active feed polishing
Applied Optics
|October 3, 2013
Summary
Active feed polishing (AFP) with a novel dual-rotor tool path addresses challenges in achieving ultrasmooth optical surfaces. This method effectively corrects surface shape and reduces roughness, meeting modern optics demands.
Area of Science:
- Optical Engineering
- Surface Metrology
- Precision Manufacturing
Background:
- Modern optics demand ultrasmooth surfaces, but current processing methods struggle to meet stringent surface figure requirements.
- Existing ultrasmooth surface processing techniques face limitations in achieving the necessary precision for advanced optical applications.
Purpose of the Study:
- To introduce and validate a novel dual-rotor tool path for active feed polishing (AFP) to overcome limitations in ultrasmooth surface generation.
- To analyze the removal error associated with the dual-rotor path and identify key influencing process parameters.
Main Methods:
- Development of a dual-rotor tool path based on motion synthesis principles for smooth trajectory connections.
- Research and proposal of a removal amount calculation method specifically for the dual-rotor path.
- Simulation analysis to determine the impact of parameters like sampling interval, eccentricity, speed ratio, and velocity on removal error.
Main Results:
- Simulation indicated that sampling interval is the primary factor influencing removal error, with eccentricity and speed ratio having lesser effects, and velocity having minimal impact.
- The study demonstrated that removal error can be effectively managed within acceptable limits through judicious selection of process parameters.
- Experimental validation on a 100 mm plane lens confirmed the feasibility and effectiveness of the dual-rotor tool path in correcting surface shape and reducing roughness.
Conclusions:
- The proposed dual-rotor tool path for active feed polishing is a viable and effective method for producing ultrasmooth optical surfaces.
- This approach successfully corrects surface figure errors and simultaneously enhances surface quality by reducing roughness.
- The dual-rotor path offers flexibility in parameter modification, simplifying the AFP mechanism while maintaining high processing accuracy.
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