Magnetorheological finishing (MRF) has been widely used in the field of modern optical machining due to the high certainty of processing. In the processing of spherical components, the detection means and sample preparation limit the acquisition of magnetorheological spherical tool influence function. In order to realize the high precision manufacturing of spherical components, the spherical removal function in the magneto-rheological polishing process is simulated and applied in practice. Based on the Preston equation, the material removal of the planar component was analyzed and the plane tool influence function model was established. On this basis, the correlation between spherical removal and plane removal was analyzed, and a simplified spherical tool influence function simulation method was proposed, and its accuracy was verified by experiments. Aiming at the processing of spherical components, the processing technology was improved and the actual processing was carried out. After processing, the PV value of the transmitted wavefront was 0.09λ, and the RMS value was 3.2 nm. The experimental results show that the spherical tool influence function simulated in this paper can be applied in actual processing and obtain a high-quality optical surface.
Subsurface damage (SSD) caused during machining process can decrease the mechanical strength of BK7 glass optical elements, which would shorten the lifetime. Rotary ultrasonic face milling (RUFM) is interest of many engineering applications, especially for machining optical glass which need the high surface quality and less SSD depth. In this paper, the effects of several critical factors (i.e. spindle speed, feed rate, and cutting depth) on machining quality and efficiency in RUFM were investigated experimentally and further analyzed. The relationships between the process parameters and the machining quality were obtained. Moreover, an optimized method was proposed for the further applications of RUFM, taking care of both machining quality and efficiency.
Magnetorheological finishing (MRF) is a deterministic optical element polishing method that achieves material removal by means of the sheared and rheo-logical behavior of magnetorheological fluids. For the magnetorheological processing optics, an experimental study of the magnetorheological processing force was carried out. It was obtained that the relationship between the process parameters and element forces in magnetorheological polishing .The process parameters in MRF are the rotation speed of the polishing wheel, the magnetic field strength, the liquid flow rate, and the immersion depth. For MRF-600 magnetorheological polishing machine with polishing wheel Φ300mm, the normal forces range from 2N to 32N.According to the fitting curve between the magnetic field and the normal forces, the force is 6 times larger than that under the zero magnetic field condition. At the same time, the polished spots were collected under different magnetic field intensity. The law of the removal rate of polishing spots was obtained.
Based on the theoretical removal function model, the internal relation between the fluid dynamic pressure parameters and the processing parameters of the magnetorheological removal function is analyzed. The main technological parameters affecting the removal function are clarified. The single-factor influence experiment was carried out for four technological parameters (liquid flow, concentration of polishing liquid, immersion depth and thickness of ribbon).The relationship curve between the single factor parameter and the removal function volume and the single factor parameter and the removal area is given. The influence of different single-factor parameters on magnetorheological removal function is obtained. The processing of a concave mirror is guided by this rule. High quality optical elements are obtained.
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