Influence of tool edge waviness on the diffraction effect of diamond-turned optics: theoretical simulation and experimental validation

Influence of multifrequency vibration on the optical performance of diamond-turned optics and its elimination method

In this work, to reveal the underlying mechanism of the influence of multifrequency vibration on the optical performance of diamond-turned optics, a systematic simulation investigation is performed using Fourier modal method and fast Fourier transformation based on a well-established surface topography model. Both the simulation results and the experimental observations demonstrate that the center area is the most heavily influenced region on the machined surface, which is closely associated with the distribution of the surface roughness under multifrequency vibration. The vibration amplitude has a visible impact on the specular reflectivity, and with an increase in vibration amplitude, the specular reflectivity in the center area obviously decreases, while the specular reflectivity in remote areas basically remains invariant. To eliminate the negative effect in relation to the vibration, a two-step process technology is developed that includes a strict spindle balance and the optimization of process parameters, particularly the depth of cut and the spindle speed. The cutting experiments further validate the effectiveness of the proposed technology for elimination of the negative effect concerning multifrequency vibration.

Influencing Factors and Theoretical Models for the Surface Topography in Diamond Turning Process: A Review

In this work, the influencing factors and corresponding theoretical models for the surface topography in diamond turning process are reviewed. The surface profile on one tool feed is the elementary unit of surface topography. The influences coupled with the models of the duplication effect of the tool edge profile, material spring back, and plastic side flow are outlined in this part. In light of the surface profile on one tool feed and "trim principle", the modeling methods of surface topography along the radial direction (2D surface topography) are commented. Moreover, the influence of the vibration between the diamond tool and workpiece on the 2D surface topography is discussed, and the theoretical models are summarized. Finally, the issues for modeling of 3D surface topography, particularly the influences of material defects, are analyzed. According to the state-of-the-art surface topography model of the diamond turned component, future work in this field is therefore predicted.