期刊
OPTICS EXPRESS
卷 27, 期 18, 页码 24885-24899出版社
OPTICAL SOC AMER
DOI: 10.1364/OE.27.024885
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类别
资金
- Science and Technology Facilities Council [ST/L001950/2]
- Engineering and Physical Sciences Research Council [EP/F031416/1]
- EPSRC [EP/P006930/1, EP/F031416/1] Funding Source: UKRI
- STFC [ST/L001950/2, ST/P003648/1] Funding Source: UKRI
Mid-spatial frequency (MSF) errors challenge freeform manufacture, not in the least due to tool-misfit. This can compromise the performance of functional surfaces and is difficult to remove by post-processing. Our previously reported work on an effective process-chain for aluminum polishing demonstrated the ability to remove MSFs by hard-tool grolishing. In this paper, we describe MSF removal on an aluminum mirror, deformed to a saddle-like freeform shape, using power spectral density (PSD) as a diagnostic. CNC Precessions bonnet polishing was optimized to minimize output MSFs, then a non-Newtonian (n-N) tool was used to attenuate the residual MSFs that were present. Our approach was distinct from the approach pioneered by University of Arizona, in that we adopted small-tool polishing on the saddle-like part, with removal rate restored by rotating the n-N tool. In order to define the optimum window of rotation speeds, the dynamic behavior of the n-N material was explored by modelling and experiments. The tool was deployed on an industrial robot, and we describe a novel 'hyper-crossing' tool-path with wide sweeping paths, which is the logical opposite of the unicursal zero-crossing paths we have previously reported. This new path has proved ideally suited to robots, given their high velocity/acceleration capabilities. Detailed results are presented from the PSD viewpoint. Published by The Optical Society under the terms of the Creative Commons Attribution 4.0 License.
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