Process decision in magnetorheological finishing guided by optical system performance indicators.

Area of Science:

• Precision Engineering
• Optical Manufacturing
• Materials Science

Background:

• Magnetorheological finishing (MRF) is a key final step in precision component manufacturing.
• Current methods focus on surface accuracy, not direct optical performance.
• A gap exists in linking process parameters to system-level optical outcomes.

Purpose of the Study:

• To propose and validate an optical performance-driven decision-making method for MRF.
• To establish a simulation linking MRF process parameters, tool marks, and optical performance.
• To enable quantitative, performance-oriented process planning in high-precision optics.

Main Methods:

• Developed a full-link simulation integrating process parameters, tool marks, and optical performance.
• Established a statistical model for process parameters and optical performance in a Ritchey-Chrétien system.
• Utilized cluster analysis, principal component analysis, and random forest for parameter optimization.

Main Results:

• Characterized MRF tool marks as a bridge between process parameters and optical performance.
• Quantified relationships between process parameters and optical performance for a Ritchey-Chrétien system.
• Determined optimal process parameter ranges through reverse searching based on performance requirements.

Conclusions:

• The proposed method enables quantitative decision-making by translating performance requirements into process parameters.
• This approach provides a performance-oriented basis for process planning in high-precision optical manufacturing.
• Optimized MRF parameter selection enhances system-level optical performance.