In view of the problem that various fused silica materials have different characteristics, which could cause differences in processability, the mechanical properties of fused silica materials were studied through nanoindentation experiments. Relationship curves between indentation load and material hardness/elastic modulus were obtained for different fused silica optics. The fracture characteristics of fused silica materials were also studied using the gradient force imprinting method, and the fracture toughness and critical load of crack generation were calculated for different fused silica materials. The ability of different fused silica materials to resist crack instability prop agation under the same process conditions was also clarified. Furthermore, the polishing removal characteristics of fused silica materials were researched, and the polishing removal efficiency of different materials was obtained through the magnetorheologi cal finishing (MRF) spotting method. It was further verified that the hardness was positively correlated with the material polishing removal efficiency. Based on the characteristics of different fused silica materials, the optical ultra -precision processing parameters could be selected. This is of great significance for low -defect and high-efficiency ultra-precision machining of optics.
Aiming at the problem of on-line real-time monitoring of grinding wheel wear state in ultra-precision grinding, the wear experimental research of fused silica optics is carried out by using acoustic emission technology. The grinding wheel wear state is determined according to the micro morphology of grinding wheel surface. On this basis, the variation law of acoustic emission signal with grinding wheel wear state is revealed, and the quantitative relationship between the root mean square value of acoustic emission signal, grinding force grinding, wheel spindle power and grinding wheel wear state is built. The wavelet packet transform is used to decompose the acoustic emission signal, studying the variation law of root mean square value of acoustic emission signal in different frequency bands under different grinding wheel wear, taking it as the feature of grinding wheel wear, and obtaining the early warning threshold for grinding wheel wear passivation according to the micro morphology of grinding wheel surface. It’s helpful to monitor and control the wear state of diamond grinding wheel in the grinding process of optics through the analysis of acoustic emission signal, so as to improve the grinding efficiency and quality of optics.
In order to suppress the polishing defects of single crystal silicon optical elements, the material removal mechanism and defect suppression technology in the polishing process of single crystal silicon were carried out. Based on the nanoindentation test, the mechanical properties of single crystal silicon were analyzed. Based on the X-ray photoelectron spectroscopy (XPS) test, the chemical element on the processed surface was studied, and then the chemical-mechanical coordinated removal mechanism in the polishing of single crystal silicon was analyzed. Then, this paper carried out the research on the bonnet polishing process of single crystal silicon optical elements. According to the experimental results, the influence of slurry characteristics on the removal efficiency and defects had been obtained, and an efficient processing method by bonnet polishing for obtaining high quality single crystal silicon elements was mastered.
Fused silica optical elements have been widely used in high power laser systems because of their good optical and mechanical properties. However, defects such as scratches on the surface/sub-surface will inevitably occur in the process of optical components. It will affect the laser damage threshold. To simulate the effect of the defect on performance of laser radiation, evolution law of the scratches in chemical etching must be predefined. In order to determine the influence of scratch, a surface scratcher used to produce a specific scratches on the surface of the elements, and its morphology was characterized and the damage test was performed. By analyzing the morphology and characteristics of the scratches during chemical processing, and recording their fluorescence effects, it is clear that the width of the scratches increases with the depth of the etching, and the laser damage resistance is gradually improved. At the same time, the initial defects of different characteristics were clarified, the evolution rate in chemical etching was not consistent, and the impact on the ability to resist laser damage was different. In general, scratch defects have severely impaired the resistance of the device to laser damage. When the damage threshold of the component without scratches is about 23J/cm2, the damage threshold of the defect location is only less than 5J/cm2. Through targeted chemical treatment processes, you can increase the threshold of most scratch damage to the level of no scratches.
In order to improve the grinding quality and efficiency of SiC elements, the influence of grinding parameters on the grinding quality was studied by using 2MK1760 ultra-precision surface grinder. Based on the surface roughness and surface precision, the relationship between grinding volume and grinding force of metal bonded and resin bonded diamond grinding wheels was researched, and it was obtained that the metal bonded grinding wheels could maintain enough sharpness during a large amount of grinding removal. The grinding force was used to characterize the grinding wheel wear, and through experiments studied the relationship between grinding parameters (including grinding depth) and the SiC material removal volume after grinding wheel one-time dressing. The results showed that different grinding depth will not affect the grinding wheel life under the same other conditions. On the basis of technological experiments, aiming at optimizing grinding efficiency and quality, resin bonded plane grinding wheel was used to grind SiC elements with three diameters of 75mm, 150mm and 320mm, and very small surface precision (PV=3.758μm) and surface roughness (RMS=35.472nm) could be obtained.
By virtue of the characteristics of high machining certainty, fast surface shape convergence and less subsurface damage, magnetorheological finishing (MRF) has been widely applied in ultra-precision machining for optics. However, the convolution of tool influence function (TIF) and the regular movement track make it difficult to avoid the deterioration of mid-spatial frequency (MSF) errors in the MRF process, which will affect the optical properties of optics. In this paper, the main factors affecting the MSF errors in grating path processing are theoretically analyzed. Under the condition of determinate polishing spot, the main influencing factors are the removal depth and processing spacing of a single scan. Through experimental research, the influence of removal depth and processing spacing of a single scan on the MSF errors in the MRF process is acquired. On this basis, the preferred parameters of removal depth and processing spacing of a single scan under specific processing conditions in the MRF process are obtained with the MSF errors of 1 nm as the evaluation index. It provides a theoretical basis and reference value for suppressing the deterioration of MSF errors of optics during MRF process and obtaining high quality optical surfaces.
The high-precision aspheric optics is difficult to achieve batch production because of its high complexity and cost in manufacturing process. Bonnet polishing is an efficient and precision polishing technology that has been widely used in aspheric optics manufacturing process. The existing aspheric bonnet polishing is mostly based on the five-axis CNC machine, but its cost is high. With the development of robot technology, it is a new, economical and effective attempt to combine robotic technology with bonnet polishing technology and apply it to manufacture the precision aspheric optics. In this paper, the research on robot-based bonnet polishing technology of aspheric optics is carried out. Firstly, the robotbased bonnet polishing equipment is introduced. Then, the control model of the robot-based bonnet polishing technology of aspheric optics is established. Finally, the aspheric polishing verification experiments are completed, and the good results are obtained. In this paper, the high-efficiency and high-precision manufacture of aspheric optics by robot-based bonnet polishing technology is realized, which greatly reduces the cost of aspheric precision manufacturing equipment, and provides a new technology choice for the high-precision, low-cost and batch production of aspheric optics.
Aiming at the disadvantage of small diameter, low efficiency, poor accuracy and can only measure sub-aperture of traditional contact surface shape measurement method to detect grinding optics surface, this paper uses non-contact laser displacement sensor, and proposes an in-situ measurement method to measure full-aperture surface of grinding optics, it has the characteristics of high measurement efficiency, high accuracy, large measurement aperture and the ability to measure full-aperture surface. This method is in-situ measurement, so it can measure full-aperture surface of optics with arbitrary aperture and shape after rough grinding, semi-precision grinding and fine grinding. Orthogonal co-directional grating measurement path can effectively avoid the influence of machine backlash. Therefore, the optics can be directly compensated according to the results of surface measurement, so that the surface of optics can meet the requirements. After the measurement is completed, a set of orthogonal measurement data are obtained, and the invalid data are manually clipped. Linear interpolation, nearest neighbor interpolation and cubic spline interpolation are used to interpolate the clipped data, and the orthogonal data are superimposed to obtain the final shape. The validity of this method is verified by the sub-aperture surface detection method, experiments show that the optimal surface measurement results can be obtained by cubic interpolation for both planar and aspheric optics. Using this method to compensate the grinding of 530mm×530mm 2-D off-axis aspheric optics, the full-aperture surface shape accuracy PV is better than 3.5μm.
Continuous phase plate (CPP) is the vital diffractive optical element in large laser devices. It is extremely difficult to manufacture owing to its random and small feature structures. Bonnet polishing (BP) has obvious advantage of high efficiency, and has great potential in high-efficient manufacturing of large optics. In the paper, BP techniques have been developed to manufacture CPP. Firstly, the relationship between the process parameters and tool influence functions (TIFs) has been analyzed, and the adjustable ranges of TIF size and efficiency have been determined. Then, a surface topography simulation model for the forecast of CPP residual errors has been established. Based on the model, the influence of TIF size on the accuracy of CPP has been simulated and analysed, meanwhile the optimized TIF has been determined. Finally, an experiment has been carried out by a 300mm×300mm CPP element. The result has shown that the residual root-mean-square (RMS) of CPP is 26 nm. Based on the optimized TIF of BP, it has been realized the high-efficient and high-precision processing of CPP in this paper, and a new technical reference for the CPP manufacturing has been provided simultaneously.
In order to improve the overall efficiency of machining and the defect quality of large aperture fused silica optics, it’s necessary to strictly control the crack defects and their depth uniformity in the first grinding process. Firstly, the morphology of three typical defects affecting the uniformity of crack depth was analyzed, which were scattered superficial sand holes, continuous linear defects and dotted linear defects. Then according to the morphology, the causes were investigated and the control techniques were proposed. The scattered superficial sand holes were caused by the large size glass powder, the diamond particles dropped from the grinding wheel and other foreign body impurities in the grinding fluid, which had been squeezed into the surface of the element by the grinding wheel. Through the clean filtration of grinding fluid, the quantity of such defects could be effectively reduced. The continuous linear defects were caused by stress concentration at the two sharp edges of the grinding wheel. Arcing the two sides of wheel could reduce the machining stress at the edges and avoid the occurrence of continuous linear defects. The dotted linear defects were caused by the stress concentration of the grooves on the surface of the wheel during grinding. After optimizing the dressing parameters to reduce the dressing force and avoid the grains of dressing wheel being embedded into the grinding wheel surface, all the grooves on the wheel surface and all the dashed line defects on the element surface disappeared practically. At the last, after integrating all the above control techniques, the grinding experiment of large scale fused silica optics was carried out. The scattered superficial sand holes, continuous linear defects and dotted linear defects on the surface of element after grinding were obviously alleviated. The crack depth of the whole aperture was between 4μm and 7μm. All the results indicated that the control techniques were efficacious.
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. To realize high precision fabrication of large-aperture optical components, MRF technology had been explored in this paper. The main factors affecting the removal efficiency were investigated by orthogonal experiment. It indicated that the influence of the immersion depth and the thickness of ribbon on removal efficiency was more remarkable than the other parameters. The process of MRF machining component is established. Finally, the 590mm × 400mm plane optical element are manufactured using the MRF, and the result are very good.
Aiming at the problem of poor uniformity and large amplitude of aspherical small-scale waviness caused by grinding aspheric surface by traditional grating parallel grinding technology, in this paper, the reasons for the poor uniformity of aspherical small-scale waviness in traditional grating parallel grinding technology are analyzed from the perspective of grinding force. Considering the influence of the uniformity of the grinding force during the grinding process on the aspherical small-scale waviness, an up-grinding grating parallel grinding method and a down-grinding grating parallel grinding method are proposed. The effects of the grinding force of the two grinding methods on the aspherical small-scale waviness uniformity are analyzed experimentally. Finally, among these three grating parallel grinding methods, the aspherical small-scale waviness obtained by the down-grinding grating parallel grinding method is the most uniform and the waviness amplitude is the smallest, the waviness amplitude is less than 2μm.
In the process of computer-controlled optical surfacing (CCOS), the key of correcting the surface error of optical components is to ensure the consistency between the simulated tool influence function and the actual tool influence function (TIF). The existing removal model usually adopts the fixed-point TIF to remove the material with the planning path and velocity, and it considers that the polishing process is linear and time invariant. However, in the actual polishing process, the TIF is a function related to the feed speed. In this paper, the relationship between the actual TIF and the feed speed (i.e. the compensation relationship between static removal and dynamic removal) is determined by experimental method. Then, the existing removal model is modified based on the compensation relationship, to improve the conformity between simulated and actual processing. Finally, the surface error modification correction test are carried out. The results show that the fitting degree of the simulated surface and the experimental surface is better than 88%, and the surface correction accuracy can be better than 1/10 λ (Λ=632.8nm).
The surface chemical composition and atomic emission spectroscopy of F atoms and CF2 molecules involved in the
processing of Atmospheric Pressure Plasma Jet (APPJ) produced from CF4 precursor has been explored. The XPS
spectra illustrated that small amount of radicals including C-CFn and CF-CFn could be introduced onto the fused silica
surface during the CF4 plasma process, the fluorocarbon radicals were generated during CF4 plasma ionization.
Moreover, the relative concentrations of excited state species of F atoms and CF2 molecules, which play significant role
in remove and fluorocarbon radicals, were acquired for CF4 plasma. The densities of F atoms increased dramatically with
increasing applied RF power, whereas CF2 molecules decreased monotonically over the same power range, the
subsequent electron impacted decomposition of plasma species after CF4 precursor fragmentation. The spectrum of the F
atoms and CF2 molecules fallowed the same tendency with the increasing concentration of gas CF4, reaching the
maximum at the 20sccm and 15sccm respectively, and then the emission intensity of reactive atoms decreased with more
CF4 molecules participating. Addition certain amount O2 into CF4 plasma resulted in promoting CF4 dissociation, O2 can
easily react with the dissociation product of CF2 molecules, which inhibit the compound of the F atoms, so with the
increasing concentration of O2, the concentration of the CF2 molecules decreased and the emission intensities of F atoms
showed the maximum at the O2/CF4 ratio of 20%. These results have led to the development of a scheme that illustrates
the mechanisms of surface chemistry reaction and the affection of plasma parameters in CF4 plasma systems with respect
to F and CF2 gas-phase species.
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