Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics

Abstract Precision grinding is a key process for realizing the use of large-aperture aspherical optical elements in laser nuclear fusion devices, large-aperture astronomical telescopes, and high-resolution space cameras. In this study, the arc envelope grinding process of large-aperture aspherical o...

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Main Authors: Changsheng Li, Lin Sun, Zhaoxiang Chen, Jianfang Chen, Qijing Lin, Jianjun Ding, Zhuangde Jiang
Format: Article
Language:English
Published: SpringerOpen 2022-08-01
Series:Chinese Journal of Mechanical Engineering
Subjects:
Online Access:https://doi.org/10.1186/s10033-022-00782-5
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author Changsheng Li
Lin Sun
Zhaoxiang Chen
Jianfang Chen
Qijing Lin
Jianjun Ding
Zhuangde Jiang
author_facet Changsheng Li
Lin Sun
Zhaoxiang Chen
Jianfang Chen
Qijing Lin
Jianjun Ding
Zhuangde Jiang
author_sort Changsheng Li
collection DOAJ
description Abstract Precision grinding is a key process for realizing the use of large-aperture aspherical optical elements in laser nuclear fusion devices, large-aperture astronomical telescopes, and high-resolution space cameras. In this study, the arc envelope grinding process of large-aperture aspherical optics is investigated using a CM1500 precision grinding machine with a maximum machinable diameter of Φ1500 mm. The form error of the aspherical workpiece induced by wheel setting errors is analytically modeled for both parallel and cross grinding. Results show that the form error is more sensitive to the wheel setting error along the feed direction than that along the lateral direction. It is a bilinear function of the feed-direction wheel setting error and the distance to the optical axis. Based on the error function above, a method to determine the wheel setting error is proposed. Subsequently, grinding tests are performed with the wheels aligned accurately. Using a newly proposed partial error compensation method with an appropriate compensation factor, a form error of 3.4 μm peak-to-valley (PV) for a Φ400 mm elliptical K9 glass surface is achieved.
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spelling doaj.art-ffb2b50eafdf4571a10e74e7a158af902022-12-22T02:45:43ZengSpringerOpenChinese Journal of Mechanical Engineering1000-93452192-82582022-08-0135111310.1186/s10033-022-00782-5Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical OpticsChangsheng Li0Lin Sun1Zhaoxiang Chen2Jianfang Chen3Qijing Lin4Jianjun Ding5Zhuangde Jiang6State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong UniversityState Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong UniversityState Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong UniversityShaanxi Qinchuan Precision CNC Machine Tool Engineering Research CoState Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong UniversityState Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong UniversityState Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong UniversityAbstract Precision grinding is a key process for realizing the use of large-aperture aspherical optical elements in laser nuclear fusion devices, large-aperture astronomical telescopes, and high-resolution space cameras. In this study, the arc envelope grinding process of large-aperture aspherical optics is investigated using a CM1500 precision grinding machine with a maximum machinable diameter of Φ1500 mm. The form error of the aspherical workpiece induced by wheel setting errors is analytically modeled for both parallel and cross grinding. Results show that the form error is more sensitive to the wheel setting error along the feed direction than that along the lateral direction. It is a bilinear function of the feed-direction wheel setting error and the distance to the optical axis. Based on the error function above, a method to determine the wheel setting error is proposed. Subsequently, grinding tests are performed with the wheels aligned accurately. Using a newly proposed partial error compensation method with an appropriate compensation factor, a form error of 3.4 μm peak-to-valley (PV) for a Φ400 mm elliptical K9 glass surface is achieved.https://doi.org/10.1186/s10033-022-00782-5Aspherical opticsWheel settingArc envelope grindingForm errorLarge aperture
spellingShingle Changsheng Li
Lin Sun
Zhaoxiang Chen
Jianfang Chen
Qijing Lin
Jianjun Ding
Zhuangde Jiang
Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics
Chinese Journal of Mechanical Engineering
Aspherical optics
Wheel setting
Arc envelope grinding
Form error
Large aperture
title Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics
title_full Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics
title_fullStr Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics
title_full_unstemmed Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics
title_short Wheel Setting Error Modeling and Compensation for Arc Envelope Grinding of Large-Aperture Aspherical Optics
title_sort wheel setting error modeling and compensation for arc envelope grinding of large aperture aspherical optics
topic Aspherical optics
Wheel setting
Arc envelope grinding
Form error
Large aperture
url https://doi.org/10.1186/s10033-022-00782-5
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