In grinding and polishing of the aspherical and freeform surface, the CCOS technology is widely used. It is a process during which errors can be corrected quantificationally by a small tool that can follow the local curves of the aspherical and freeform surface. It commonly uses constant pressure during polishing, and thus the desired amount of material to be remove depends on the dwell time. This thesis the pressure regulation is introduced into the CCOS polishing system. The pressure can be controlled in real time in the process of processing, and the application of pressure control in CCOS polishing is realized. The main characteristic of this technology is that the desired amount of material to be removed is controlled by both the polishing pressure and the dwell time. Firstly, a mathematical model was established for the variable pressure polishing process. Then the machining efficiency and the influence of pressure error on machining quality are simulated and analyzed. Finally, a material removal experiment that applied sinusoidal pressure was carried out on a K9 material mirror. Results showed that frequency of the measured pressure is the same as that of the ideal sinusoidal polishing pressure. The spatial period of the measured surface profile is the same as that of surface profile obtained by simulation of the sinusoidal polishing process. The surface profile error is within 17%. In this thesis, variable pressure polishing was achieved. Compared with the constant pressure CCOS polishing technology, the variable pressure CCOS polishing technology adds one more degree of freedom to the polishing process. It need have higher requirements for the pressure active control system, such as the output pressure range, response speed and precision. These performance parameters can affect the processing results. Therefore the key to developing the variable pressure CCOS polishing technology is to research the polishing tool, which must have high performance pressure active control system.
Ultrasonic elliptical vibration cutting (UEVC) is attracting much attention in ultra-precision machining of brittle materials as it was found be able to increase the critical depth of cut (dc) of brittle materials. However, there are few studies on the prediction of dc for UEVC of brittle materials. In this study, a predictive model was developed for the prediction of dc in microgroove plunge-cutting with respect to several factors, including the distance from transient surface to target surface (DTSTS), the actual undeformed chip thickness (UCT), the critical UCT (tc) and crack length (Cm). Experiments on plunge-cutting of KDP crystal were conducted. Results showed the predicted dc matches well with the experimental ones.
Ultra-precision noncircular optical components, e.g. hyperbolic quadrupole in mass spectrometer, can be machined by diamond turning assisted by slow tool servo (STS). However, the bandwidth of STS is usually small, which limits the STS's capability in following the required tool path, leading to a large form error. To reduce the form error, this paper proposes an approach to apply variable spindle speed (VSS) to STS-based turning. Design of the VSS trajectory based on the noncircular profile of the optical component was investigated in detail. To validate the proposed approach, simulation on the application of VSS in the STS-based turning process was established and applied to the machining of typical noncircular optical components. Simulation results show that the proposed approach is effective in reducing the requirement on the bandwidth of the STS, resulting in higher form accuracy of the machined noncircular optical components.
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