Dwell time for optical fabrication using the modified discrete convolution matrix method.

More accurate dwell time calculation methods are necessary to achieve superior error convergence in producing optically critical components. Although the discrete convolution matrix method finds widespread application, it still has approximate errors in the non-uniform discrete form of tool paths. To address this issue, this paper introduced a modified matrix elements method and presented the general Voronoi polygon area weight calculation forms under different tool path discretization forms. The mechanism is explained through analysis and the validity is verified by numerical simulation. The modified method significantly improved uniformity distribution and accuracy in computation of surface residuals. This improvement holds promise as a guiding principle for the fabrication of ultra-precision optical components.

Tool mark prediction on the surface of large-aperture mirrors via magnetorheological finishing.

The magnetorheological finishing (MRF) of surfaces often results in tool mark errors. A prediction model can effectively guide subsequent processing, necessitating thorough research. To address this issue, this paper introduces an enhanced continuous tool influence function method. This method involves sub dwell time convolution with varying tool influence functions, enabling tool mark prediction. Numerical simulations demonstrate the proposed method's effectiveness, while the data size is estimated to confirm its economic properties. Subsequently, a MRF experiment was conducted, affirming the practicability through power spectral density evaluation. A fast algorithm is given to guide tool mark predictions on large-aperture mirrors fabrication engineering subjected to sub-aperture polishing.

Evolution mechanism of scratch removal based on the implementation of magnetorheological finishing.

Scratches on optical components induce laser damage and limit the increase in laser power. Magnetorheological finishing (MRF) is a highly deterministic optical manufacturing technology that can improve the surface roughness of optical components. Although MRF has exhibited significant potential for reducing subsurface damage and removing scratches, the principle and mechanism behind the scratch removal are not sufficiently understood. In this study, the theory of fluid mechanics is used to analyze the pressure, velocity, and particle trajectory distribution near a scratch. A physical model was developed for the differential removal of scratches at the bottom and surface of the optical components. The morphological evolution of the scratch was predicted during removal, and detailed experiments were performed to verify the effectiveness of the proposed model. The results indicate that scratches expand laterally rather than being completely removed. Furthermore, scratch removal efficiency is greater when the removal direction is perpendicular to the scratch rather than being parallel. This study offers an intrinsic perspective for a comprehensive understanding of the MRF technique used for scratch removal, which can be beneficial for removing scratches from aspherical optical systems.

Accurately predicting the tool influence function to achieve high-precision magnetorheological finishing using robots.

Industrial robots with six degrees-of-freedom have significant potential for use in optical manufacturing owing to their flexibility, low cost, and high space utilisation. However, the low trajectory accuracy of robots affects the manufacturing accuracy of optical components when combined with magnetorheological finishing (MRF). Moreover, general robot trajectory-error compensation methods cannot compensate for the running errors of large robots with high precision. To address this problem, a three-dimensional (3D) tool influence function (TIF) model based on inverse distance interpolation is developed in this study to accurately predict the TIF of different polishing gaps. A high-precision robot-MRF polishing strategy based on variable TIFs and surface shape accuracy of polished optics is proposed to achieve high-precision manufacturing without compensating for trajectory errors. Subsequently, the accuracy of a ϕ420 mm fused silica mirror is experimentally verified to be from 0.11 λ RMS to 0.013 λ RMS. This validates that the robot-MRF can achieve high-precision polishing without compensating for trajectory errors. Furthermore, the proposed model will promote the applications of industrial robots in optical manufacturing and will serve as a reference in the field of intelligent optical manufacturing.

High-precision magnetorheological finishing based on robot by measuring and compensating trajectory error.

The 6-DOF industrial robot has wide application prospects in the field of optical manufacturing because of its high degrees of freedom, low cost, and high space utilisation. However, the low trajectory accuracy of robots will affect the manufacturing accuracy of optical components when the robots and magnetorheological finishing (MRF) are combined. In this study, aiming at the problem of the diversity of trajectory error sources of robot-MRF, a continuous high-precision spatial dynamic trajectory error measurement system was established to measure the trajectory error accurately, and a step-by-step and multistage iterations trajectory error compensation method based on spatial similarity was established to obtain a high-precision trajectory. The experimental results show that compared with the common model calibration method and general non-model calibration method, this trajectory error compensation method can achieve accurate compensation of the trajectory error of the robot-MRF, and the trajectory accuracy of the Z-axis is improved from PV > 0.2 mm to PV < 0.1 mm. Furthermore, the finishing accuracy of the plane mirror from 0.066λ to 0.016λ RMS and the finishing accuracy of the spherical mirror from 0.184λ RMS to 0.013λ RMS using the compensated robot-MRF prove that the robot-MRF has the ability of high-precision polishing. This promotes the application of industrial robots in the field of optical manufacturing and lays the foundation for intelligent optical manufacturing.

Fabrication and photoelectric response of poly(allylamine hydrochloride)/PM thin films by layer-by-layer deposition technique.

Thin films of poly(allylamine hydrochloride) (PAH) and bacteriorhodopsin (bR) embedded in purple membrane (PM) have been prepared by layer-by-layer (LBL) self-assembly technique. The results obtained by UV-Vis spectroscopy and atomic force microscopy (AFM) analysis showed that the biological activity of bR was preserved and PM fragments could be well oriented onto the ITO substrate. A photo-electrochemical cell with the structure of ITO/(PAH/PM)(n)/electrolyte (0.5M KCl)/Pt was fabricated and studied. The photocurrent peaks of (PAH/PM)(6) corresponding to light-on and light-off were about 200 and 100 nA/cm(2), respectively, with the former enhanced 30% higher than that of the reference films made of (PDAC/PM)(6).