Abstract
In the technology of computer-controlled optical surfacing (CCOS), the convergence of surface form error has a close relationship with the distribution of surface form error, the calculation of dwell time, tool influence function (TIF) and path planning. The distribution of surface form error directly reflects the difference in bulk material removal depth across a to-be-polished surface in subsequent corrective polishing. In this paper, the effect of path spacing and bulk material removal depth on the residual error have been deeply investigated based on basic simulation experiments excluding the interference factors in the actual polishing process. With the relationship among the critical evaluation parameters of the residual error (root-mean-square (RMS) and peak-to-valley (PV)), the path spacing and bulk material removal depth are mathematically characterized by the proposed RMS and PV maps, respectively. Moreover, a variable pitch path self-planning strategy based on the distribution of surface form error is proposed to optimize the residual error distribution. In the proposed strategy, the influence of different bulk material removal depths caused by the distribution of surface form error on residual error is compensated by fine adjustment of the path spacing according to the obtained path spacing optimization models. The simulated experimental results demonstrate that the residual error optimization strategy proposed in this paper can significantly optimize the overall residual error distribution without compromising the convergence speed. The optimized residual error distribution obtained in sub-regions of the polished surface is more uniform than that without optimization and is almost unaffected by the distribution of parent surface form error.
Highlights
Whether it is in the high-end fields such as the defense industry, aviation and aerospace, or in the civilian fields of medical devices, mobile phones, cameras, etc., high-precision optical components are playing an increasingly important role
Once the surface form error distribution of the actual workpiece was determined, we could get the variation in bulk material removal depth across the surface and could consider the use of fine-tuning of the path spacing to compensate for the effect of surface form error on the residual error, as well as achieve the purpose of optimizing the residual error distribution
This paper deeply studied and analyzed the influence law of bulk material removal depth and path spacing on residual error
Summary
Whether it is in the high-end fields such as the defense industry, aviation and aerospace, or in the civilian fields of medical devices, mobile phones, cameras, etc., high-precision optical components are playing an increasingly important role. There are increasingly higher requirements for surface form error, medium frequency error, surface roughness and subsurface damage of optical components [1]. With the introduction of aspherical and free form surface design methods, precision devices composed of optical components have been unified in terms of portability and functionality. This poses a great challenge to the ultra-precision machining of optical components.
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