Rotary-coordinate and shuttling-element cutting strategy for ultra-precision diamond turning of optical microstructures.

Toolpath generation techniques have become increasingly critical in ultra-precision diamond turning for optical microstructures due to the dramatically enhanced geometrical complexity of the machined region. However, the conventionally used spiral toolpath is required for interpolation from the structural models, leading to random instability of the feeding axis and additional profile error between the toolpath and designed structures, which means an enlarged effect on the machining quality in ultra-precision machining. In this paper, a rotary-coordinate and shuttling-element cutting strategy based on integrated geometrical modelling and spiral toolpath generation is presented for ultra-precision turning of optical microstructures. Using the innovative rotary-coordinate and shuttling-element cutting method, the point clouds for the micro-structured modelling can be scattered along the spiral shape which can be directly fitted as the final toolpath. A series of simulation and cutting experiments have been carried out to realize the effectiveness of this method, and it is found that the preparation time in diamond turning can be significantly reduced along with ameliorating the machining quality.

E-PVT: enhanced position-velocity-time scheduler for computer-controlled optical finishing with comprehensive considerations of dynamics constraints, continuity and efficiency.

Deterministic computer-controlled optical finishing is an essential approach for achieving high-quality optical surfaces. Its determinism and convergence rely heavily on precise and smooth motion control to guide the machine tool over an optical surface to correct residual errors. One widely supported and smooth motion control model is position-velocity-time (PVT), which employs piecewise cubic polynomials to describe positions. Our prior research introduced a PVT-based velocity scheduling method, demonstrating sub-nanometer level convergence in ion beam figuring (IBF) processes. However, three challenges remained. Firstly, this method relies on quadratic programming, resulting in computational intensiveness for dense tool paths. Secondly, the dynamics constraints and velocity and acceleration continuities are not comprehensively considered, limiting the full potential of PVT-based control. Thirdly, no compensation mechanism existed when dynamics constraints are exceeded. In this study, in response to these challenges, we proposed the Enhanced PVT (E-PVT) method, reducing the time complexity from O(n3) to O(n) while fully addressing dynamics constraints and continuities. A novel compensation method utilizing particle swarm optimization was proposed to address situations where dynamics constraints might be exceeded while maintaining the overall processing efficiency. Validation through simulation and experimentation confirmed the improved performance of E-PVT.

Restraint of the mid-spatial frequency error on optical surfaces by multi-jet polishing.

Nowadays, the mid-spatial frequency (MSF) error existing in the optical surface after polishing is still a great challenge for the ultra-precision manufacturing of optical components. MSF error severely deteriorates the performances of optical components such as causing small-angle scattering and reducing imaging contrast. In this paper, multi-jet polishing (MJP) was proposed to restrain the MSF error, whose tool influence function (TIF) was relatively more complicated and adjustable than the TIFs of other tools. The results demonstrated that MJP had a superior ability to reduce the ripple error, and the path spacing and nozzle orientation angle both had a significant effect on the MSF error of the polished surface. The optimization of nozzle orientation angle under different path spacings was conducted to achieve a high surface quality. This study contributes to the ultra-precision manufacturing of optical components, achieving a low MSF error together with high finishing efficiency.

Curvature effect-based modeling and experimentation of the material removal in polishing optical surfaces using a flexible ball-end tool.

Optical surfaces with high quality have been widely applied in high-tech industries for their excellent performances. To precision manufacture those surfaces efficiently and effectively, various machining technologies involved become extremely crucial. As one of the promising ultra-precision machining technologies, inflated or solid elastic tool polishing has attracted more attention for its own superiority. However, there is still lack of understanding on material removal mechanisms especially with the consideration of curvature effect, and it is of great importance to determine the surface quality and form control in ultra-precision polishing process. In this paper, originating from the famous macro-scale Preston equation, the curvature effect-based material removal model in polishing using a flexible ball-end tool has been developed successfully on the basis of two key sub-models, one is the generic model of effective relative velocity and the other refers to the semi-experimental contact pressure model. A series of spot polishing experiments subsequently are conducted on concave surfaces with a curvature radius range from 75 mm to 225 mm. The experimentally measured section profiles of polishing spots do match well with the predicted data, which verifies the effectiveness of the proposed material removal model. On the measured polishing spots, it is also observed that there have two nonuniform material removal phenomena, one is analyzed along the central axis and the other is discussed by two regions symmetrical about the central axis. Compared with the effective relative velocity, it is found that, the contact pressure is more sensitive to curvature effect by investigating the variation of maximum removal depth within a broader curvature radius range from 75 mm to 1000 mm. This study can provide a valuable foundation for polishing optical surfaces with deterministic removal.

Multi-tool optimization for computer controlled optical surfacing.

With the rapid development of precision technologies, the demand of high-precision optical surfaces has drastically increased. These optical surfaces are mainly fabricated with computer controlled optical surfacing (CCOS). In a CCOS process, a target surface removal profile is achieved by scheduling the dwell time for a set of machine tools. The optimized dwell time should be positive and smooth to ensure convergence to the target while considering CNC dynamics. The total run time of each machine tool is also expected to be balanced to improve the overall processing efficiency. In the past few decades, dwell time optimization for a single machine tool has been extensively developed. While the methods are applicable to multi-tool scenarios, they fail to consider the overall contributions of multiple tools simultaneously. In this paper, we conduct a systematic study on the strategies for multi-tool dwell time optimization and propose an innovative method for simultaneously scheduling dwell time for multiple tools for the first time. First, the influential factors to the positiveness and smoothness of dwell time solutions for a single machine tool are analyzed. The compensation strategies that minimize the residual while considering the CNC dynamics limit are then proposed. Afterwards, these strategies are extended to the proposed multi-tool optimization that further balances the run time of machine tools. Finally, the superiority of each strategy is carefully studied via simulation and experiment. The experiment is performed by bonnet polishing a 60 mm × 60 mm mirror with three tools of different diameters (i.e., 12 mm, 8 mm, and 5 mm). The figure error of the mirror is reduced from 45.42 nm to 11.18 nm root mean square in 13.28 min. Moreover, the measured polishing result well coincides with the estimation, which proves the effectiveness of the proposed method.

Universal dwell time optimization for deterministic optics fabrication.

Computer-Controlled Optical Surfacing (CCOS) has been greatly developed and widely used for precision optical fabrication in the past three decades. It relies on robust dwell time solutions to determine how long the polishing tools must dwell at certain points over the surfaces to achieve the expected forms. However, as dwell time calculations are modeled as ill-posed deconvolution, it is always non-trivial to reach a reliable solution that 1) is non-negative, since CCOS systems are not capable of adding materials, 2) minimizes the residual in the clear aperture 3) minimizes the total dwell time to guarantee the stability and efficiency of CCOS processes, 4) can be flexibly adapted to different tool paths, 5) the parameter tuning of the algorithm is simple, and 6) the computational cost is reasonable. In this study, we propose a novel Universal Dwell time Optimization (UDO) model that universally satisfies these criteria. First, the matrix-based discretization of the convolutional polishing model is employed so that dwell time can be flexibly calculated for arbitrary dwell points. Second, UDO simplifies the inverse deconvolution as a forward scalar optimization for the first time, which drastically increases the solution stability and the computational efficiency. Finally, the dwell time solution is improved by a robust iterative refinement and a total dwell time reduction scheme. The superiority and general applicability of the proposed algorithm are verified on the simulations of different CCOS processes. A real application of UDO in improving a synchrotron X-ray mirror using Ion Beam Figuring (IBF) is then demonstrated. The simulation indicates that the estimated residual in the 92.3 mm × 15.7 mm CA can be reduced from 6.32 nm Root Mean Square (RMS) to 0.20 nm RMS in 3.37 min. After one IBF process, the measured residual in the CA converges to 0.19 nm RMS, which coincides with the simulation.

Time-varying tool influence function model of bonnet polishing for aspheric surfaces.

For bonnet polishing of an aspheric surface, the tool influence function (TIF) is inevitably time varying, induced by the different surface curvatures on the aspheric surface. Accordingly, this paper investigated how the surface curvature affects the bonnet-workpiece contact area, and then presented a time-varying TIF model. The time-varying TIF was modeled based on the finite element analysis and kinematics analysis methods, and validated by experiments. The experimental results exhibited good agreement with the theoretical results. The proposed method can forecast the TIF for different polishing positions on aspheric surfaces, and provide the theoretical foundation for dynamic compensation of aspheric surface polishing.

Fluid jet-array parallel machining of optical microstructure array surfaces.

Optical microstructure array surfaces such as micro-lens array surface, micro-groove array surface etc., are being used in more and more optical products, depending on its ability to produce a unique or particular performance. The geometrical complexity of the optical microstructures array surfaces makes them difficult to be fabricated. In this paper, a novel method named fluid jet-array parallel machining (FJAPM) is proposed to provide a new way to generate the microstructure array surfaces with high productivity. In this process, an array of abrasive water jets is pumped out of a nozzle, and each fluid jet simultaneously impinges the target surface to implement material removal independently. The jet-array nozzle was optimally designed firstly to diminish the effect of jet interference based on the experimental investigation on the 2-Jet nozzles with different jet intervals. The material removal and surface generation models were built and validated through the comparison of simulation and experimental results of the generation of several kinds of microstructure array surfaces. Following that, the effect of some factors in the process was discussed, including the fluid pressure, nozzle geometry, tool path, and dwell time. The experimental results and analysis prove that FJAPM process is an effective way to fabricate the optical microstructure array surface together with high productivity.

Fluid jet-array parallel machining of optical microstructure array surfaces: publisher's note.

This publisher's note amends the funding section of [Opt. Express 25, 22710 (2017)].

Unicursal random maze tool path for computer-controlled optical surfacing.

A novel unicursal random maze tool path is proposed in this paper, which can not only implement uniform coverage of the polishing surfaces, but also possesses randomness and multidirectionality. The simulation experiments along with the practical polishing experiments are conducted to make the comparison of three kinds of paths, including maze path, raster path, and Hilbert path. The experimental results validate that the maze path can warrant uniform polishing and avoid the appearance of the periodical structures in the polished surface. It is also more effective than the Hilbert path in restraining the mid-spatial frequency error in computer-controlled optical surfacing process.

Dwell-time algorithm for polishing large optics.

The calculation of the dwell time plays a crucial role in polishing precision large optics. Although some studies have taken place, it remains a challenge to develop a calculation algorithm which is absolutely stable, together with a high convergence ratio and fast solution speed even for extremely large mirrors. For this aim, we introduced a self-adaptive iterative algorithm to calculate the dwell time in this paper. Simulations were conducted in bonnet polishing (BP) to test the performance of this method on a real 430 mm × 430 mm fused silica part with the initial surface error PV=1741.29 nm, RMS=433.204 nm. The final surface residual error in the clear aperture after two simulation steps turned out to be PV=11.7 nm, RMS=0.5 nm. The results confirm that this method is stable and has a high convergence ratio and fast solution speed even with an ordinary computer. It is notable that the solution time is usually just a few seconds even on a 1000 mm × 1000 mm part. Hence, we believe that this method is perfectly suitable for polishing large optics. And not only can it be applied to BP, but it can also be applied to other subaperture deterministic polishing processes.

Coating-Free Superhydrophobic Hard Surfaces by Electric Discharge Machining with a Magnetic-Assisted Self-Assembly Sheet Electrode.

Artificial superhydrophobic surfaces hold significant potential in various domains, encompassing self-cleaning, droplet manipulation, microfluidics, and thermal management. Consequently, there is a burgeoning demand for cost-effective, mass-producible, and easily fabricated superhydrophobic surfaces for commercial and industrial applications. This research introduces an efficient, uncomplicated method for constructing hierarchical structures on hard substrates such as binderless tungsten carbide (WC) and glass substrates. The WC substrates were processed by using electrical discharge machining (EDM) with a magnetic-assisted self-assembly sheet electrode. The resultant surfaces comprised micropillars/microgrooves and diminutive craters formed by discharge and ablation, respectively. These surfaces exhibited superior hydrophobic properties, which can be attributed to the modified surface energy and surface texture construction. Our study indicates that a superhydrophobic surface can be achieved on a textured binderless WC. The maximum contact angle and minimum roll-off angle of the hierarchical structure induced by EDM with a magnetic-assisted self-assembly sheet electrode are about 158 and 5°, respectively. The advancing and receding angles are about 161° ± 2 and 157° ± 3, respectively, when the base is tilted at 3°. Furthermore, we have successfully replicated this superhydrophobic structured surface on glass substrates utilizing glass molding technology. This innovative approach to creating superhydrophobic surfaces on hard materials paves the way for the mass production of functional structures on other materials, such as metallic glass, titanium alloy, and mold steel. Most crucially, the proposed fabrication technique offers a straightforward, cost-effective route for creating functional surfaces, rendering it attractive for large-scale industrial production due to its considerable application prospects.

The mechanical, wear, antibacterial properties and biocompatibility of injectable restorative materials under wet challenge.

OBJECTIVES: To evaluate the mechanical, wear, antibacterial properties, and biocompatibility of injectable composite materials. METHODS: Two injectable composite resins (GU and BI), one flowable composite resin (FS), and one flowable compomer (DF), in A2 shade, were tested. Mechanical properties were tested via three-point bending test immediately after preparation and after 1-day, 7-day, 14-day, and 30-day water storage. Under water-PMMA slurry immersion, specimens were subjected to a 3-body wear test (10,000 cycles) against stainless steel balls, while the roughness, wear depth, and volume loss were recorded. After 1-day and 3-day MC3T3-E1 cell culture, cell viability was evaluated with CCK-8 test kits, while the cell morphology was observed under CLSM and SEM. Antibacterial properties on S. mutans were assessed via CFU counting, CLSM, and SEM observation. SPSS 26.0 was used for statistical analysis (α = 0.05). RESULTS: The mechanical properties were material-dependent and sensitive to water storage. Flexural strength ranked GU > FS > BI > DF at all testing levels. Three nanocomposites had better wear properties than DF. No significant difference on 1-day cell viability was found, but DF showed significantly lower cell proliferation than nanocomposites on 3-day assessment. GU and FS had more favourable cell adhesion and morphology. CFU counting revealed no significant difference, while FS presented a slightly thicker biofilm and BI showed relatively lower bacteria density. CONCLUSIONS: Injectable nanocomposites outperformed the compomer regarding mechanical properties, wear resistance, and biocompatibility. The tested materials presented comparable antibacterial behaviours. Flowable resin-based composites' performances are affected by multiple factors, and their compositions can be attributed. CLINICAL SIGNIFICANCE: A profound understanding of the mechanical, wear, and biological properties of the restorative material is imperative for the clinical success of dental restorations. The current study demonstrated superior properties of highly filled injectable composite resins, which imply their wider indications and better long-term clinical performances.

Surface Roughness Prediction in Ultra-Precision Milling: An Extreme Learning Machine Method with Data Fusion.

This paper pioneers the use of the extreme learning machine (ELM) approach for surface roughness prediction in ultra-precision milling, leveraging the excellent fitting ability with small datasets and the fast learning speed of the extreme learning machine method. By providing abundant machining information, the machining parameters and force signal data are fused on the feature level to further improve ELM prediction accuracy. An ultra-precision milling experiment was designed and conducted to verify our proposed data-fusion-based ELM method. The results show that the ELM with data fusion outperforms other state-of-art methods in surface roughness prediction. It achieves an impressively low mean absolute percentage error of 1.6% while requiring a mere 18 s for model training.

Process Chain for Ultra-Precision and High-Efficiency Manufacturing of Large-Aperture Silicon Carbide Aspheric Mirrors.

A large-aperture silicon carbide (SiC) aspheric mirror has the advantages of being light weight and having a high specific stiffness, which is the key component of a space optical system. However, SiC has the characteristics of high hardness and multi-component, which makes it difficult to realize efficient, high-precision, and low-defect processing. To solve this problem, a novel process chain combining ultra-precision shaping based on parallel grinding, rapid polishing with central fluid supply, and magnetorheological finishing (MRF) is proposed in this paper. The key technologies include the passivation and life prediction of the wheel in SiC ultra-precision grinding (UPG), the generation and suppression mechanism of pit defects on the SiC surface, deterministic and ultra-smooth polishing by MRF, and compensation interference detection of the high-order aspheric surface by a computer-generated hologram (CGH). The verification experiment was conducted on a Ø460 mm SiC aspheric mirror, whose initial surface shape error was 4.15 µm in peak-to-valley (PV) and a root-mean-square roughness (Rq) of 44.56 nm. After conducting the proposed process chain, a surface error of RMS 7.42 nm and a Rq of 0.33 nm were successfully obtained. Moreover, the whole processing cycle is only about 216 h, which sheds light on the mass production of large-aperture silicon carbide aspheric mirrors.

Simulation and Experimental Study of Laser Processing NdFeB Microarray Structure.

NdFeB materials are widely used in the manufacturing of micro-linear motor sliders due to their excellent permanent magnetic properties. However, there are many challenges in processing the slider with micro-structures on the surface, such as complicated steps and low efficiency. Laser processing is expected to solve these problems, but few studies have been reported. Therefore, simulation and experiment studies in this area are of great significance. In this study, a two-dimensional simulation model of laser-processed NdFeB material was established. Based on the overall effects of surface tension, recoil pressure, and gravity, the temperature field distribution and morphological characteristics with laser processing were analyzed. The flow evolution in the melt pool was discussed, and the mechanism of microstructure formation was revealed. In addition, the effect of laser scanning speed and average power on machining morphology was investigated. The results show that at an average power of 8 W and a scanning speed of 100 mm/s, the simulated ablation depth is 43 µm, which is consistent with the experimental results. During the machining process, the molten material accumulated on the inner wall and the outlet of the crater after sputtering and refluxing, forming a V-shaped pit. The ablation depth decreases with the increment of the scanning speed, while the depth and length of the melt pool, along with the height of the recast layer, increase with the average power.

Editorial for the Special Issue on "Frontiers of Ultra-Precision Machining".

Ultra-precision machining is a multi-disciplinary research area that is an important branch of manufacturing technology [...].

Synthesis of Green and Red-Emitting Polymethyl Methacrylate Composites Grafted from ZnAl2O4:Mn-Bonded GO via Surface-Initiated Atom Transfer Radical Polymerization.

A novel dual green and red-emitting photoluminescent polymer composite ZnAl2O4:Mn-bonded GO/polymethyl methacrylate (PMMA) was synthesized in a single-step reaction by surface-initiated atom transfer radical polymerization (SI-ATRP). The polymer chain was surface-initiated from the ZnAl2O4:Mn/GO, and the final products have a homogenous photoluminescent property from ZnAl2O4:Mn and better mechanical properties strengthened by graphene oxide (GO). The morphologies of ZnAl2O4:Mn/GO and the polymer composites were verified by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). X-ray diffraction analysis (XRD) revealed the two valence states of Mn (Mn2+, Mn4+) existing in the ZnAl2O4 host lattice, while Fourier-transform infrared spectroscopy (FTIR) spectra proved the transference of the active group, C-Br, from the initiator to the monomer during the polymerization. Gel permeation chromatography (GPC) shows the narrow dispersity of polymer composites fabricated through SI-ATRP. The SEM and FTIR results show the successful 'graft' of the polymer chains from the surface of ZnAl2O4:Mn/GO. The dual green and red-emitting polymer composites were synthesized, confirmed by the photoluminescence (PL) and photoluminescence excitation (PLE) results.

Experimental Investigation on the Effect of Surface Shape and Orientation in Magnetic Field Assisted Mass Polishing.

Magnetic field assisted finishing (MFAF) technology has been widely used in industries such as aerospace, biomedical, and the optical field for both external and internal surface finishing due to its high conformability to complex surfaces and nanometric surface finishing. However, most of the MFAF methods only allow polishing piece-by-piece, leading to high post-processing costs and long processing times with the increasing demand for high precision products. Hence, a magnetic field-assisted mass polishing (MAMP) method was recently proposed, and an experimental investigation on the effect of surface posture is presented in this paper. Two groups of experiments were conducted with different workpiece shapes, including the square bar and roller bar, to examine the effect of surface orientation and polishing performance on different regions. A simulation of magnetic field distribution and computational fluid dynamics was also performed to support the results. Experimental results show that areas near the chamber wall experience better polishing performance, and the surface parallel or inclined to polishing direction generally allows better shearing and thus higher polishing efficiency. Both types of workpieces show notable polishing performance where an 80% surface roughness improvement was achieved after 20-min of rough polishing and 20-min of fine polishing reaching approximately 20 nm.

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity.

Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields.