Development of pseudo-random diamond turning method for fabricating freeform optics with scattering homogenization

In this paper, a novel pseudo-random diamond turning (PRDT) method is proposed for the fabrication of freeform optics with scattering homogenization by means of actively eliminating the inherent periodicity of the residual tool marks. The strategy for accurately determining the spiral toolpath with pseudo-random vibration modulation is deliberately explained. Spatial geometric calculation method is employed to determine the toolpath in consideration of cutting tool geometries, and an iteration algorithm is further introduced to enhance the computation efficiency. Moreover, a novel two degree of freedom fast tool servo (2-DOF FTS) system with decoupled motions is developed to implement the PRDT method. Taking advantage of a novel surface topography generation algorithm, theoretical surfaces generated by using the calculated toolpaths are obtained, the accuracy of the toolpath generation and the efficiency of the PRDT method for breaking up the inherent periodicity of tool marks are examined. A series of preliminary cutting experiments are carried out to verify the efficiency of the proposed PRDT method, the experimental results obtained are in good agreement with the results obtained by numerical simulation. In addition, the results of scattering experiments indicate that the proposed PRDT method will be a very promising technique to achieve the scattering homogenization of machined surfaces with complicated shapes.