Lei R L, Li Y, Lin W M, et al. Research on the calculation method of the ultra-precision turning trajectory of large-vector high-convex cylinders[J]. Opto-Electron Eng, 2021, 48(3): 200192. doi: 10.12086/oee.2021.200192
Citation: Lei R L, Li Y, Lin W M, et al. Research on the calculation method of the ultra-precision turning trajectory of large-vector high-convex cylinders[J]. Opto-Electron Eng, 2021, 48(3): 200192. doi: 10.12086/oee.2021.200192

Research on the calculation method of the ultra-precision turning trajectory of large-vector high-convex cylinders

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  • Array microstructure optical elements are widely used in various beam homogenization occasions, but conventional processing methods cannot meet the accuracy requirements of large-sagittal convex cylindrical arrays. In this paper, the ultra-precision turning forming method is used to analyze the main factors affecting diamond turning, the sequential search method and the binary search method are designed to find the turning track, and the advantages and disadvantages of the two methods are compared. Furthermore, the binary search method is successfully found by combining the Matlab software turning trajectory and the numerical control program. As proof-of-concept demonstrations, turning experiments are carried on an ultra-precision lathe, and a large-vector high-array microstructure with a surface profile error of 135 nm is obtained. It proves that the force binary search method can accurately obtain the turning trajectory, and this method can be applied to both spherical and aspherical contours, showing important engineering application value.
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  • Overview: Array microstructured optical elements are widely used in various beam homogenization occasions, with complex structures and extremely high surface shape accuracy requirements. The microstructures of large-sag high-convex cylindrical arrays have the characteristics of high sagittal height, large diameter, small seam, and high surface shape accuracy. It is often difficult for conventional processing methods to meet the accuracy requirements. As a ultra-precision turning forming method, the diamond tip has a micron-level structure, and the processing accuracy is not limited by the height of the microstructure, which is a very potential method for processing the microstructure of the large array of high convex cylindrical arrays.

    How to ensure the machining accuracy is an important problem that needs to be solved in ultra-precision turning. This paper analyzes the main factors that affect diamond turning-turning trajectories. Increasing the turning trajectory accuracy can improve the turning surface accuracy and obtain a good machining surface shape. This article analyzes and compares two methods, namely sequential search method and binary search method, to find the best turning trajectory, and each method has its own advantages and disadvantages. The sequential search method can obtain a high-precision turning trajectory, but the calculation amount will gradually increase as the stepping distance decreases, which leads to lower efficiency. The binary search method can quickly obtain the turning trajectory, and the calculation amount is relatively small. So the calculation time is short, which greatly improves the turning efficiency. Combined with actual production applications, improving efficiency is one of the important issues that need to be considered. Therefore, this paper chooses the binary search method to find the turning contour trajectory.

    The binary search method can be used to find the turning trajectories of both spherical and aspherical contours. Combined with laboratory conditions, the experiment took the spherical contour as an example, and the spherical turning trajectory was successfully generated through numerical control programs. Furthermore, turning experiments on ultra-precision turning machine tools were carried out, with the turning results being analyzed using the least square method. The original curve is compared with the fitted curve, and the difference curve is obtained. It is found that the contour error of the workpiece after processing is 135 nm, and the expected surface shape and good surface contour error are basically obtained. This article provides a theoretical basis for how to find the turning trajectory of the large-vector convex cylindrical array microstructure, and has important practical application value.

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