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Nonlinear dwell-time algorithm for freeform surface generation by atmospheric-pressure plasma processing.

Xing Su, Xiaobin Yue

    Optics Express
    |October 12, 2022
    PubMed
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    This study introduces a new nonlinear dwell-time algorithm for atmospheric pressure plasma processing (APPP) to accurately machine freeform surfaces. The algorithm controls volumetric removal, overcoming APPP

    Area of Science:

    • Optical Engineering
    • Materials Science
    • Manufacturing Technology

    Background:

    • Atmospheric pressure plasma processing (APPP) offers high material removal rates for computer-controlled optical surfacing (CCOS).
    • APPP's time-variant removal characteristics introduce nonlinearity into the CCOS process, complicating dwell-time calculations.
    • Accurate freeform surface generation requires addressing these nonlinearities in dwell-time algorithms.

    Purpose of the Study:

    • To develop and validate a nonlinear dwell-time algorithm for freeform surface generation using APPP.
    • To model freeform surface generation by controlling volumetric removal for theoretical basis.
    • To explore the algorithm's applicability to APPP with time-varying characteristics via simulations.

    Main Methods:

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  • Development of a nonlinear dwell-time algorithm based on controlling volumetric removal.
  • Modeling of freeform surface generation by controlling volumetric removal.
  • Numerical simulations to assess algorithm applicability with time-varying tool influence functions.
  • Experimental validation through the creation of a freeform surface.

    • Main Results:

    • The proposed nonlinear dwell-time algorithm effectively manages the time-variant removal characteristics of APPP.
    • Numerical simulations confirmed the algorithm's applicability in freeform generation.
    • Successful fabrication of a freeform surface validated the algorithm's practical use.
    • The study demonstrates the algorithm's capability with time-variant tool influence functions.

    Conclusions:

    • The developed nonlinear dwell-time algorithm is effective for freeform surface generation using APPP.
    • Controlling volumetric removal is a viable strategy to address APPP nonlinearities in CCOS.
    • The algorithm provides a robust solution for fabricating complex optical surfaces with APPP.
    • This research validates the algorithm for practical applications in advanced optical manufacturing.