Effect of Robot Motion Accuracy on Surface Form during Computer-Controlled Optical Surfacing Process

被引:2
作者
Chen, Yong-Tong [1 ]
Liu, Mingyu [2 ]
Cao, Zhong-Chen [3 ]
机构
[1] Beijing Normal Univ, Sch Govt, Dept Informat Management, Beijing 100089, Peoples R China
[2] Univ Nottingham, Fac Engn, Mfg Metrol Team, Nottingham NG8 1BB, England
[3] Tianjin Univ, Sch Mech Engn, Tianjin 300350, Peoples R China
来源
APPLIED SCIENCES-BASEL | 2022年 / 12卷 / 23期
关键词
computer-controlled optical surfacing; motion accuracy; material removal model; normal error; form accuracy;
D O I
10.3390/app122312301
中图分类号
O6 [化学];
学科分类号
0703 ;
摘要
Nowadays, large-aperture optical components are increasingly used in high-power laser systems, remote-sensing satellites, and space-based astronomical telescopes. Fabricating these surfaces with submicron-scale shape accuracy and a nanoscale surface finish has been a great challenge for the optical industry, especially for hard and difficult-to-machine materials. Thus, to achieve the high-efficiency and high-precision polishing of large-aperture aspherical optical parts, this study combined robotic machining technology with computer-controlled optical surfacing (CCOS) technology and investigated the effect of robot motion accuracy on the surface topography of workpieces during polishing. First, a material removal model considering the normal error of the polishing tool was developed based on contact mechanics, kinematic theory, and the abrasion mechanism. Next, in combination with the polishing trajectory, the surface morphology and form accuracy after polishing were predicted under different normal-error conditions. Then, preliminary experiments were conducted to verify the model. The experimental data agreed with the simulation results, showing that as the normal error increased from 0 degrees to 0.5 degrees and 1 degrees, the peak-to-valley (PV) values of the surface profile of the optical element decreased from 5.42, 5.28, and 4.68 mu m to 3.97, 4.09, and 4.43 mu m, respectively. The corresponding convergence rates were 26.8%, 22.5%, and 5.3%. The root mean square (RMS) values decreased from 0.754, 0.895, and 0.678 mu m to 0.593, 0.620, and 0.583 mu m, with corresponding convergence rates of 21.4%, 30.7% and 14.0%, respectively. Moreover, a higher motion accuracy enabled the polishing robot to reduce the mid- and high-frequency errors of the optical element.
引用
收藏
页数:13
相关论文
共 19 条
[1]   Super-smooth finishing of diamond turned hard X-ray molding dies by combined fluid jet and bonnet polishing [J].
Beaucamp, Anthony ;
Namba, Yoshiharu .
CIRP ANNALS-MANUFACTURING TECHNOLOGY, 2013, 62 (01) :315-318
[2]   Theoretical and experimental investigation of surface generation in swing precess bonnet polishing of complex three-dimensional structured surfaces [J].
Cao, Zhong-Chen ;
Cheung, Chi Fai ;
Ho, Lai Ting ;
Liu, Ming Yu .
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY, 2017, 50 :361-371
[3]   RAPID FABRICATION OF LARGE ASPHERIC OPTICS [J].
JONES, RA ;
PLANTE, RL .
PRECISION ENGINEERING-JOURNAL OF THE AMERICAN SOCIETY FOR PRECISION ENGINEERING, 1987, 9 (02) :65-70
[4]   Genetic algorithm-powered non-sequential dwell time optimization for large optics fabrication [J].
Kang, Hyukmo ;
Wang, Tianyi ;
Choi, Heejoo ;
Kim, Daewook .
OPTICS EXPRESS, 2022, 30 (10) :16442-16458
[5]   Multi-tool optimization for computer controlled optical surfacing [J].
Ke, Xiaolong ;
Wang, Tianyi ;
Zhang, Zili ;
Huang, Lei ;
Wang, Chunjin ;
Negi, Vipender S. ;
Pullen, Weslin C. ;
Choi, Heejoo ;
Kim, Daewook ;
Idir, Mourad .
OPTICS EXPRESS, 2022, 30 (10) :16957-16972
[6]   New and improved technology for manufacture of GMT primary mirror segments [J].
Kim, Dae Wook ;
Burge, James H. ;
Davis, Johnathan M. ;
Martin, Hubert M. ;
Tuell, Michael T. ;
Graves, Logan R. ;
West, Steve C. .
ADVANCES IN OPTICAL AND MECHANICAL TECHNOLOGIES FOR TELESCOPES AND INSTRUMENTATION II, 2016, 9912
[7]   Rigid conformal polishing tool using non-linear visco-elastic effect [J].
Kim, Dae Wook ;
Burge, James H. .
OPTICS EXPRESS, 2010, 18 (03) :2242-2257
[8]   Advances in the design and manufacturing of novel freeform optics [J].
Kumar, Sumit ;
Tong, Zhen ;
Jiang, Xiangqian .
INTERNATIONAL JOURNAL OF EXTREME MANUFACTURING, 2022, 4 (03)
[9]  
Li S., 2017, CCOS TECHNOLOGY BASE
[10]   Mid-Spatial Frequency Error (PSD-2) of optics induced during CCOS and full-aperture polishing [J].
Liao, D. ;
Yuan, Z. ;
Tang, C. ;
Xie, R. ;
Chen, X. .
JOURNAL OF THE EUROPEAN OPTICAL SOCIETY-RAPID PUBLICATIONS, 2013, 8 :13031.1-13031.5