Abstract
In diamond-machined freeform manufacturing processes, a tool-tip often leaves behind characteristic mid-spatial frequency (MSF) structures on the optical surface. Unwanted movement between the tool-tip and the part results in MSF structures with random variations. Here, we analyze the effects of these MSF structures on the system's optical performance and derive simple analytic estimates for the optical transfer function in terms of the parameters of these structures. These expressions are expected to aid in MSF tolerancing.
Highlights
Precision freeform manufacturing allows the fabrication of surfaces with large numbers of degrees of freedom
We explored the effects on the optical transfer function (OTF) of wavefront errors, including quadratic aberrations [3] as well as mid-spatial frequency (MSF) groove structures due to subaperture tools [4]
Two types of MSF groove errors common in freeform manufacturing processes were analyzed: parallel straight grooves resulting from diamond milling, and concentric circular grooves resulting from diamond turning
Summary
Precision freeform manufacturing allows the fabrication of surfaces with large numbers of degrees of freedom These processes typically involve the use of subaperture tools, which leave behind surface grooves whose characteristic frequencies are between those of figure and roughness. We explored the effects on the optical transfer function (OTF) of wavefront errors, including quadratic aberrations [3] as well as MSF groove structures due to subaperture tools [4]. In the latter case, two types of MSF groove errors common in freeform manufacturing processes were analyzed: parallel straight grooves resulting from diamond milling, and concentric circular (or spiral) grooves resulting from diamond turning. For readers more interested in the formulas than the formal derivations, Sec. 5 provides a self-contained summary of the main results
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