Mid-high-frequency error suppression of small optical aspheric molds
Applied Optics
|May 3, 2023
Summary
This study introduces a simulation method to optimize polishing parameters for tungsten carbide molds, significantly reducing surface errors. The new approach enhances convergence rates and achieves high-quality surface finishing faster than traditional methods.
Area of Science:
- Optical Engineering
- Materials Science
- Manufacturing Processes
Background:
- Small optical tungsten carbide aspheric molds often suffer from mid-high-frequency errors.
- Efficiently suppressing these errors is crucial for high-precision optical component manufacturing.
Purpose of the Study:
- To develop a rapid simulation method for selecting critical process parameters to suppress mid-high-frequency errors.
- To propose and validate a faster, high-quality multi-tool combination smoothing method for aspheric surfaces.
Main Methods:
- Convolution simulation of the tool influence function (TIF) to predict residual errors.
- Optimization of RMS and Ra parameters through simulation.
- Design and application of a disc-shaped polishing tool with fine microstructure for multi-tool smoothing.
Main Results:
- Simulation optimizations for RMS and Ra converged to 9.3 nm and 5.347 nm, respectively, with improved convergence rates (40% and 7.9%).
- Global Ra of the aspheric surface was reduced from 5.9 nm to 4.5 nm in 5.5 minutes.
- Excellent low-frequency error (PV 0.0781 µm) was maintained.
Conclusions:
- The proposed simulation and multi-tool smoothing method effectively suppresses mid-high-frequency errors in aspheric molds.
- This approach offers faster processing times and improved surface quality for optical manufacturing.
