Open Loop Fuzzy Optimizer for Computer Controlled Polishing

Abstract

Computer Control Polishing (CCP) was developed during the last four decades to administrate the operation of almost all polishing methods. To this end, , enhancing the simulation of CCP process not only improves the quality of final products but also trims operation time and, consequently, leads to accelerate the manufacturing of optical lenses. In this study, a new method has been developed and applied for simulation of polishing process based on discretizing continuous toolpath to small distance—100 µm in length—which accordingly heightens the accuracy of simulation process. Smoothing feed rate fluctuation over toolpath is also a side benefit of the represented method that precludes damage to machine and workpiece. To proceed with CCP, we conducted an open-loop fuzzy controller approach to optimize the tool feed rate distribution over the toolpath. The method has the ability to optimize feed rate to reduce surface error for a variety of toolpaths and lens geometries. The simulation and experimental results of series of tests on a BK7 plano-plano lens show about 85% of surface roughness improvement. High percentage of improvement and the resemblance between simulation and experimental results respectively confirmed the accuracy of simulation method and the capability of optimization algorithm.