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Modified dwell time optimization model and its applications in subaperture polishing.

Zhichao Dong, Haobo Cheng, Hon-Yuen Tam

    Applied Optics
    |June 13, 2014
    PubMed
    Summary

    A new dwell time optimization model for subaperture polishing effectively suppresses edge effects. This iterative method offers compatibility with various tool paths and tool influence functions (TIFs), achieving high convergence rates and reduced processing times for precision optics.

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    Area of Science:

    • Precision Engineering
    • Optical Manufacturing
    • Surface Metrology

    Background:

    • Deterministic subaperture polishing requires precise dwell time optimization.
    • Existing models struggle with arbitrary tool paths and asymmetric tool influence functions (TIFs).
    • Edge effects remain a challenge in achieving uniform surface quality.

    Purpose of the Study:

    • To present a modified, iterative dwell time optimization model for deterministic subaperture polishing.
    • To enhance compatibility with diverse tool paths and TIFs, including asymmetric ones.
    • To suppress edge effects and improve overall polishing efficiency and accuracy.

    Main Methods:

    • Developed a modified optimization model using iterative and numerical methods.
    • Incorporated extended surface forms and tool paths for edge effect mitigation.
    • Validated the model's compatibility with arbitrary paths, multiple TIFs, and asymmetric TIFs.

    Main Results:

    • Achieved a smooth, non-negative dwell time map with a 99.6% RMS convergence rate in simulation.
    • Demonstrated significant reduction in optimization time compared to discrete convolution and linear equation models.
    • Optimized TIF size (~1/7 workpiece size) and path interval (~1/8-1/10 TIF size) for different spatial frequencies.
    • Experimental results on a Φ920mm paraboloid and Φ100mm plane yielded RMS values of 0.016λ and 0.013λ, respectively.

    Conclusions:

    • The proposed iterative dwell time model is highly effective for subaperture polishing.
    • It offers superior compatibility and efficiency over traditional methods.
    • The model successfully validates its feasibility for precision manufacturing of optical components.