Mid-spatial frequency removal on aluminum free-form mirror.
Mid-spatial frequency removal on aluminum free-form mirror.
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DOI：
10.1364/oe.27.024885
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发表时间：
2019-09
期刊：
影响因子：
3.8
通讯作者：
Hongyu Li;D. Walker;Xiao Zheng;Xing Su;Lunzhe Wu;Christina Reynolds;Guoyu Yu;Tony Li;Peng Zhang
中科院分区：
文献类型：
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作者：
Hongyu Li;D. Walker;Xiao Zheng;Xing Su;Lunzhe Wu;Christina Reynolds;Guoyu Yu;Tony Li;Peng Zhang
中空间频率（MSF）误差挑战自由形状制造，而不是由于工具不匹配。这可能会损害功能表面的性能，并且很难通过后处理去除。我们之前报道的关于铝抛光的有效工艺链的工作表明，通过硬工具抛光可以去除msf。在本文中，我们描述了MSF去除铝镜，变形为鞍状自由形状，使用功率谱密度（PSD）作为诊断。优化CNC旋进阀盖抛光以最小化输出msf，然后使用非牛顿（n-N）工具来衰减存在的残余msf。我们的方法与亚利桑那大学首创的方法不同，我们采用小工具对鞍状部分进行抛光，通过旋转n-N工具恢复去除率。为了确定最佳的旋转速度窗口，通过建模和实验对n-N材料的动态行为进行了探索。该工具已部署在工业机器人上，我们描述了一种具有宽扫描路径的新型“超交叉”工具路径，这与我们之前报道的通用零交叉路径在逻辑上是相反的。考虑到机器人的高速/加速能力，这条新路径已被证明非常适合机器人。从PSD的角度给出了详细的结果。
Mid-spatial frequency (MSF) errors challenge freeform manufacture, not in the least due to tool-misfit. This can compromise the performance of functional surfaces and is difficult to remove by post-processing. Our previously reported work on an effective process-chain for aluminum polishing demonstrated the ability to remove MSFs by hard-tool grolishing. In this paper, we describe MSF removal on an aluminum mirror, deformed to a saddle-like freeform shape, using power spectral density (PSD) as a diagnostic. CNC Precessions bonnet polishing was optimized to minimize output MSFs, then a non-Newtonian (n-N) tool was used to attenuate the residual MSFs that were present. Our approach was distinct from the approach pioneered by University of Arizona, in that we adopted small-tool polishing on the saddle-like part, with removal rate restored by rotating the n-N tool. In order to define the optimum window of rotation speeds, the dynamic behavior of the n-N material was explored by modelling and experiments. The tool was deployed on an industrial robot, and we describe a novel 'hyper-crossing' tool-path with wide sweeping paths, which is the logical opposite of the unicursal zero-crossing paths we have previously reported. This new path has proved ideally suited to robots, given their high velocity/acceleration capabilities. Detailed results are presented from the PSD viewpoint.