30 June 2016 Aspheric mismatch of rigid tools
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Proceedings Volume 10009, Third European Seminar on Precision Optics Manufacturing; 1000904 (2016) https://doi.org/10.1117/12.2235536
Event: Third European Seminar on Precision Optics Manufacturing, 2016, Teisnach, Germany
Many processes applied in Computer Controlled Optical Surfacing (CCOS)1–4 utilise a conformal polishing tool (e.g. the Precessions™ process) which is well suited to correct surface errors that are larger than or similar in size as the contact area between tool and surface, applying a different dwell time as needed. However, due to the conformal nature of the tool it has no significant effect on surface errors with smaller dimensions: the peaks and valleys of the error will be polished equally.

To remove these smaller dimension errors with a conformal tool is impractical. The preferred approach therefore is to apply a sufficiently rigid tool of sufficient size so that it preferentially removes material from the peaks and not from the valleys. A larger tool is capable of smoothing surfaces where the peaks are further apart and also benefits from a larger removal rate, reducing the total process time.

To achieve a uniform contact the form of the tool should be the inverse of the local form of the surface. This is trivial for spherical or plano surfaces, but present problems when the surface is aspherical. The mismatch between a rigid tool and the workpiece increases with the size of the tool for a given asphere, which leads to an upper limit of the tool size that can be used.

The work reported in this article presents a numerical analysis of the mismatch of rigid tools applied on E-ELT prototype segments. It can be readily applied to aspheric or free-form surfaces for which an analytical approach is difficult or impossible and furthermore it provides a detailed analysis of the form of this mismatch, including spatial frequency content. Additionally, an analysis and experimental work is presented to determine the applicability of sub-aperture rigid tools for the polishing of E-ELT segments.
© (2016) COPYRIGHT Society of Photo-Optical Instrumentation Engineers (SPIE). Downloading of the abstract is permitted for personal use only.
Wilhelmus A. C. M. Messelink, Wilhelmus A. C. M. Messelink, "Aspheric mismatch of rigid tools", Proc. SPIE 10009, Third European Seminar on Precision Optics Manufacturing, 1000904 (30 June 2016); doi: 10.1117/12.2235536; https://doi.org/10.1117/12.2235536


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