Forced-based tool deviation induced form error identification in single-point diamond turning of optical spherical surfaces

Dai, Yuqi; Jiang, Jiankai; Zhang, Guoqing; Luo, Tong

doi:10.1016/j.precisioneng.2021.04.001

Cited by 19 publications

(2 citation statements)

References 33 publications

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“…SPDT is an excellent machining method with high efficiency, low cost, and ease of forming complex surfaces. Therefore, SPDT turning is the most commonly used method for machining metallic optical components [ 16 , 17 , 18 ]. However, SPDT turning leaves periodic turning tool patterns on the surface of the workpiece, which can increase light scatter and degrade the system’s image quality [ 19 , 20 ].…”

Section: Introductionmentioning

confidence: 99%

Nano-Precision Processing of NiP Coating by Magnetorheological Finishing

Peng

et al. 2023

Nanomaterials

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NiP coating has excellent physicochemical properties and is one of the best materials for coating optical components. When processing NiP coatings on optical components, single-point diamond turning (SPDT) is generally adopted as the first process. However, SPDT turning produces periodic turning patterns on the workpiece, which impacts the optical performance of the component. Magnetorheological finishing (MRF) is a deterministic sub-aperture polishing process based on computer-controlled optical surface forming that can correct surface shape errors and improve the surface quality of workpieces. This paper analyzes the characteristics of NiP coating and develops a magnetorheological fluid specifically for the processing of NiP coating. Based on the basic Preston principle, a material removal model for the MRF polishing of NiP coating was established, and the MRF manufacturing process was optimized by orthogonal tests. The optimized MRF polishing process quickly removes the SPDT turning tool pattern from the NiP coating surface and corrects surface profile errors. At the same time, the surface quality of the NiP coating has also been improved, with the surface roughness increasing from Ra 2.054 nm for SPDT turning to Ra 0.705 nm.

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Section: Introductionmentioning

confidence: 99%

Nano-Precision Processing of NiP Coating by Magnetorheological Finishing

Peng

et al. 2023

Nanomaterials

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“…tool setting errors, is also crucial factor which may deteriorate surface quality [14]. By analyzing the relationship between tool setting errors and cutting force forms, Dai et al [15] developed a force-based model and well predicted the three dimension form of a convex spherical surface in UPDT. According to the multi-body system theory and a homogeneous transformation matrix, Liu et al [16] built up a machining error model to investigate the coordinate distortions and form errors of MLA.…”

Section: Introductionmentioning

confidence: 99%

A theoretical and experimental investigation into tool setting induced form error in diamond turning of micro-lens array

Guo

Zhang

et al. 2022

Int J Adv Manuf Technol

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Micro-lens array (MLA) has been widely used for 3D imaging etc., due to its excellent functional performances. Ultra-precision diamond turning (UPDT) offers a satisfying solution to the fabrication of micro-lens array with sub-micron form accuracy and nanometric surface roughness. However, the deviation between spindle to tool tip, i.e. tool setting error, is a crucial factor deteriorating form accuracy in UPDT. This study focuses on discussing the effect of tool setting errors on form error in UPDT of MLA. Firstly, a theoretical model was established to analyze the form error of MLA induced by tool setting.Moreover, a new two-step tool setting method was employed for reducing or eliminating the tool setting errors. Finally, experiments were carried out considering the tool setting effect in UPDT of MLA. The results indicated that the proposed tool setting method can achieve a high-precision accuracy and the distribution of form error obtained from experiments was in a good agreement with theoretical model.Signi cantly, the study draws up an understanding of the tool setting effect on form accuracy in UPDT of MLA with the further improvement.

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