Simulation and experimental verification of the precision finishing method for optical free-form surface segmentation

Area of Science:

• Optical engineering
• Manufacturing technology
• Surface metrology

Background:

• Free-form surfaces are critical in aerospace optics, demanding high-precision manufacturing.
• Current machining methods for aluminum alloy free-form surfaces face challenges in quality and efficiency.

Purpose of the Study:

• To develop an efficient numerical control (NC) machining method for aluminum alloy free-form surfaces.
• To improve processing quality and overall efficiency through surface segmentation.

Main Methods:

• Surface segmentation involves curvature-based region classification (convex, concave, saddle-shaped).
• Fuzzy c-means clustering refines surface segmentation.
• Voronoi diagrams are used to determine surface boundaries.
• Comparison with conventional machining via UG simulation and experimental validation.

Main Results:

• UG simulation showed a 12.18% reduction in machining path and 13.92% in machining time.
• Experimental results demonstrated a 12.28% reduction in machining path length and 12.56% in machining time.
• The segmentation method significantly enhances machining efficiency and quality.

Conclusions:

• The proposed free-form surface segmentation approach is practical and effective.
• This method offers a viable solution for improving the machining of complex optical surfaces.
• Enhanced efficiency and quality in free-form surface machining are achievable.