Edge control in a computer controlled optical surfacing process using a heterocercal tool influence function

Area of Science:

• Optical Engineering
• Manufacturing Technology

Background:

• Edge effects pose significant challenges in computer-controlled optical surfacing (CCOS).
• Traditional CCOS methods struggle with accuracy and edge residual removal, especially in small overhang conditions.

Purpose of the Study:

• To introduce and validate a new 'heterocercal' tool influence function (TIF) for controlling edge effects in CCOS.
• To enhance manufacturing efficiency for large optical systems by mitigating edge residuals.

Main Methods:

• Theoretical analysis of the 'heterocercal' TIF concept.
• Physical realization and experimental validation of the 'heterocercal' TIF in CCOS facilities.
• Simulation of the TIF's performance in controlling material removal at edges.

Main Results:

• The 'heterocercal' TIF effectively transfers material removal from the inner surface to the edge.
• Experimental and simulation results demonstrate good agreement, validating the TIF's efficacy.
• Significant control over edge effects and surface error convergence was achieved under large tool-to-mirror size-ratio conditions.

Conclusions:

• The 'heterocercal' TIF offers a viable solution to the long-standing edge effect problem in CCOS.
• This advancement improves manufacturing efficiency for large-scale optical projects, such as the Thirty Meter Telescope's tertiary mirror.