Abstract
The material removal depth in the pre-polishing stage of the precision optics is usually tens of microns to remove the subsurface damage and grinding marks left by the previous grinding process. This processing of the upstand edge takes a large part of the time at this stage. The purpose of this paper is to develop a method that can reduce the edge effect and largely shorten the processing time of the pre-polishing stage adopting the semirigid (SR) bonnet. The generation of the edge effect is presented based on the finite element analysis of the contact pressure at the edge zone firstly. Then, some experimentations on the edge effect are conducted, and the results proved that the SR bonnet tool can overhang the workpiece edge in the pre-polishing stage to reduce the width and height of the upstand edge to largely shorten the subsequent processing time of it. In addition, there exists a perfect overhang ratio, which generates the upstand edge with the smallest width and height, with no damage to the bonnet tool in the meantime. In addition, one combination of the pre-polishing parameters is concluded according to this method, which can be safely adopted in practical process.
Highlights
Nowadays, computer-controlled optical surfacing (CCOS) technology has been widely used to manufacture the telescope mirrors, optical lens, and molds, etc. [1]
Considering that only one line was polished under each condition in the experiments conducted in Section 3, and the bonnet tool deals with the edge only at the end of each line within an extremely short time, it cannot reflect that the bonnet tool can not be damaged after polishing the whole surface under these corresponding conditions
Tentative investigations on reducing the edge effect of adopting the SR bonnet have been done in this paper
Summary
Computer-controlled optical surfacing (CCOS) technology has been widely used to manufacture the telescope mirrors, optical lens, and molds, etc. [1]. Computer-controlled optical surfacing (CCOS) technology has been widely used to manufacture the telescope mirrors, optical lens, and molds, etc. There still exists a significant challenge, which is the control of the part edge combined with the speed of processing to enhance the processing accuracy. Unlike ion beam figuring or fluid jet polishing [2], there are edge effects in most CCOS processes such as small tool polishing [3], magnetorheological finishing [4], bonnet polishing [5], and so on. The edge effect would lead to edge-roll, and it needs to be further corrected with smaller tools. It takes a large part of the processing time
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