叶斯哲, 王朋, 张昊, 回长顺. 子孔径范成法铣磨半球及超半球光学整流罩[J]. 应用光学, 2023, 44(6): 1362-1370. DOI: 10.5768/JAO202344.0605002
引用本文: 叶斯哲, 王朋, 张昊, 回长顺. 子孔径范成法铣磨半球及超半球光学整流罩[J]. 应用光学, 2023, 44(6): 1362-1370. DOI: 10.5768/JAO202344.0605002
YE Sizhe, WANG Peng, ZHANG Hao, HUI Changshun. Sub-aperture generating method for grinding hemispherical and hyper-hemispherical optical dome[J]. Journal of Applied Optics, 2023, 44(6): 1362-1370. DOI: 10.5768/JAO202344.0605002
Citation: YE Sizhe, WANG Peng, ZHANG Hao, HUI Changshun. Sub-aperture generating method for grinding hemispherical and hyper-hemispherical optical dome[J]. Journal of Applied Optics, 2023, 44(6): 1362-1370. DOI: 10.5768/JAO202344.0605002

子孔径范成法铣磨半球及超半球光学整流罩

Sub-aperture generating method for grinding hemispherical and hyper-hemispherical optical dome

  • 摘要: 为攻克高陡度球面光学零件成型技术,以半球及超半球红外光学整流罩为研究对像,提出了一种子孔径铣磨加工方法。对传统范成法铣磨成型理论进行拓展,将球面离散为一系列子孔径环带,砂轮沿环带“步进”运动,拼接成型得到完整的球面。分析了成型球面与三轴机床位置坐标之间的转换关系,对加工运动轨迹进行仿真,开展半径误差补偿验证实验及变速进给参数优化实验,提出变半径铣磨法解决超半球加工材料过切问题。对长径比分别为0.5(半球)和0.55 (超半球)的热压硫化锌、镁铝尖晶石整流罩开展成型工艺试验,加工表面各点矢高差<4 µm,表面粗糙度Ra<1.5 µm。实验结果表明:该方法为高陡度球面加工提供了有效的解决方案。

     

    Abstract: In order to overcome the molding technology of high-steep spherical optical parts, a sub-aperture grinding method was proposed, taking the hemispherical and hyper-hemispherical infrared optical domes as the research object. The traditional generating method grinding forming theory is expanded, the spherical surface is discretized into a series of sub-aperture rings, the grinding wheel "steps" along the ring, and a complete spherical surface is obtained by splicing and forming. In this paper, the transformation relationship between the forming spherical surface and the position coordinates of the three-axis machine tool was analyzed, the machining motion trajectory was simulated, and the radius error compensation verification experiment and the variable feed parameter optimization experiment were conducted. A method of variable radius grinding was proposed to solve the problem of over-cutting of hyper-hemisphere machining materials. The forming process test was carried out on the hot-pressed zinc sulfide and magnesium-aluminum spinel spherical dome with the aspect ratios of 0.5 (hemisphere) and 0.55 (hyper-hemisphere) respectively, the sag height difference of each point on the processing surface < 4 μm, and the surface roughness Ra<1.5 μm. The results show that the method is feasible and can provide an effective solution for deep high gradient spherical processing.

     

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