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.

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.

Semi-supervised angular super-resolution method for autostereoscopic 3D surface measurement.

Autostereoscopic 3D measuring systems are an accurate, rapid, and portable method for in situ measurements. These systems use a micro-lens array to record 3D information based on the light-field theory. However, the spatial-angular-resolution trade-off curtails their performance. Although learning models were developed for super-resolution, the scarcity of data hinders efficient training. To address this issue, a novel, to the best of our knowledge, semi-supervised learning paradigm for angular super-resolution is proposed for data-efficient training, benefiting both autostereoscopic and light-field devices. A convolutional neural network using motion estimation is developed for a view synthesis. Subsequently, a high-angular-resolution autostereoscopic system is presented for an accurate profile reconstruction. Experiments show that the semi-supervision enhances view reconstruction quality, while the amount of training data required is reduced by over 69%.

Fe3O4/PMMA with Well-Arranged Structures Synthesized through Magnetic Field-Assisted Atom Transfer Radical Polymerization.

Particle- or fiber-reinforced polymer composites with controlled orientations are attracting interest and applications producing innovative materials, biological constructs, and energy devices. To gain the controlled orientations, filed-assisted synthesis is widely selected for its easy operation and control. In this paper, we designed magnetic field-assisted equipment and synthesized a magnetic polymer composite Fe3O4/PMMA with a well-arranged layers structure by combining the magnetic field with atom transfer radical polymerization (ATRP). During the polymerization of polymer composites, the magnetic nanoparticles were surrounded by monomers. With the growth of polymer chains, the magnetic particles pushed polymer chains to move according to a specific direction and form a well-arranged structure under the magnetic fields. The existence of a well-arranged layered structure of the composites gives potential guidance for controlling the micro-structure by adding an extra field during the polymerization process. The experimental results provided a possible design to influence the macroscale properties through control of the micro-structure of polymer composites.

Active Compliance Smart Control Strategy of Hybrid Mechanism for Bonnet Polishing.

Compliance control strategies have been utilised for the ultraprecision polishing process for many years. Most researchers execute active compliance control strategies by employing impedance control law on a robot development platform. However, these methods are limited by the load capacity, positioning accuracy, and repeatability of polishing mechanisms. Moreover, a sophisticated actuator mounted at the end of the end-effector of robots is difficult to maintain in the polishing scenario. In contrast, a hybrid mechanism for polishing that possesses the advantages of serial and parallel mechanisms can mitigate the above problems, especially when an active compliance control strategy is employed. In this research, a high-frequency-impedance robust force control strategy is proposed. It outputs a position adjustment value directly according to a contact pressure adjustment value. An open architecture control system with customised software is developed to respond to external interrupts during the polishing procedure, implementing the active compliance control strategy on a hybrid mechanism. Through this method, the hybrid mechanism can adapt to the external environment with a given contact pressure automatically instead of relying on estimating the environment stiffness. Experimental results show that the proposed strategy adapts the unknown freeform surface without overshooting and improves the surface quality. The average surface roughness value decreases from 0.057 um to 0.027 um.

Autostereoscopic 3D Measurement Based on Adaptive Focus Volume Aggregation.

Autostereoscopic three-dimensional measuring systems are a kind of portable and fast precision metrology instrument. The systems are based on integral imaging that makes use of a micro-lens array before an image sensor to observe measured parts from multiple perspectives. Since autostereoscopic measuring systems can obtain longitudinal and lateral information within single snapshots rapidly, the three-dimensional profiles of the measured parts can be reconstructed by shape from focus. In general, the reconstruction process consists of data acquisition, pre-processing, digital refocusing, focus measures, and depth estimation. The accuracy of depth estimation is determined by the focus volume generated by focus measure operators which could be sensitive to the noise during digital refocusing. Without prior knowledge and surface information, directly estimated depth maps usually contain severe noise and incorrect representation of continuous surfaces. To eliminate the effects of refocusing noise and take advantage of traditional focus measure methods with robustness, an adaptive focus volume aggregation method based on convolutional neural networks is presented to optimize the focus volume for more accurate depth estimation. Since a large amount of data and ground truth are costly to acquire for model convergence, backpropagation is performed for every sample under an unsupervised strategy. The training strategy makes use of a smoothness constraint and an identical distribution constraint that restricts the difference between the distribution of the network output and the distribution of ideal depth estimation. Experimental results show that the proposed adaptive aggregation method significantly reduces the noise during depth estimation and retains more accurate surface profiles. As a result, the autostereoscopic measuring system can directly recover surface profiles from raw data without any prior information.

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.

Fabrication of the high-precision micro-structure array using a phase shift modulation of superimposed oscillation in ultra-precision grinding.

Various micro-structure surface texturing methods have been used to produce optical functional surface in the grinding, such as the textured grinding wheel, wheel path control and off-spindle-axis grinding. However, those grinding technologies are inherently challenged to employ in large-scale surface grinding due to the extremely high requirement for wheel cutting profile dressing. In this study, a novel phase shift modulation based on wheel oscillation motion was proposed to generate the micro-structure array in ultra-precision grinding. The phase shift effect involved in the surface micro-structure generation is investigated, in which the role of the second phase shift on superimposed mode and micro-waviness forms is discussed. A theoretical model based on the tool superimposed oscillation is established to study the micro-structure texture generation mechanism by considering the second phase shift. The influence of modulation frequency in the case of phase shift and out of phase shift on the surface texture generation both for the striation pattern and micro-structure is compared to clarify the transition between the continuous grooves and the discrete micro-structure array. The study indicates that the phase shift modulation represents a novel paradigm for fabricating micro-structure array with considerable capability and high efficiency in ultra-precision grinding.

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.

Self super-resolution autostereoscopic 3D measuring system using deep convolutional neural networks.

Autostereoscopy technology can provide a rapid and accurate three-dimensional (3D) measurement solution for micro-structured surfaces. Elemental images (EIs) are recorded within one snapshot and the measurement accuracy can be quantified from the disparities existing in the 3D information. However, a trade-off between the spatial and the angular resolution of the EIs is a major obstacle to the improvement on the measurement results. To address this issue, an angular super-resolution algorithm based on deep neural networks is proposed to construct a self super-resolution autostereoscopic (SSA) 3D measuring system. The proposed super-resolution algorithm can generate novel perspectives between the neighboring EIs so that the angular resolution is enhanced. The proposed SSA 3D measuring system can achieve self super-resolution on its measurement data. A comprehensive comparison experiment was conducted to verify the feasibility and technical merit of the proposed measuring system. The results show that the proposed SSA system can significantly improve the resolution of the measuring data by around 4 folds and enhance the measurement accuracy to a sub-micrometer level with lower standard deviations and biases.

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.

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.

Study of deterministic surface micro-texture generation in ultra-precision grinding considering wheel oscillation.

Ultra-precision grinding is crucial for manufacturing high-end optics and molds, while the unbalanced wheel vibration is inevitable and becomes even more critical in surface generation, which resulted in undesired waviness and micro-texture on the ground surface. In this paper, to understand and control the micro-texture generation, a theoretical model has been developed to predict the deterministic surface micro-texture generation resulted from unbalanced tool vibration in ultra-precision grinding, in which the overlap trajectories of grinding wheel with an arc cutting edge were analyzed and calculated. The simulation work was performed and a double phase mechanism involved in deterministic textural pattern and structure has been revealed. Both theoretical and experimental results proved that phase shift is an important factor to determine micro-texture evolution in the ultra-precision grinding process. On this basis, a novel tool path strategy has been proposed to fabricate deterministic micro-structure by coordinating oscillation motion of the grinding wheel and phase shift control, in which a rhombus-shaped micro-structure array can be generated. A small adjustment for the phase shift was conducted and it was found that the more complex micro-texture with different textural patterns and micro-structure can be machined. The results indicated that the phase control for the tool path planning is an effective method to fabricate flexible and tunable micro-texture surfaces in ultra-precision grinding.

Characterization of Surface Topography Variation in the Ultra-Precision Tool Servo-Based Diamond Cutting of 3D Microstructured Surfaces.

Previous models of the relative tool-work vibration are not generalized to represent the surface generation mechanism in the ultra-precision tool servo-based diamond cutting (UTSDC) of three-dimensional (3D) microstructured surfaces. This is due to the fact that the tool-work vibration in UTSDC is no longer a steady harmonic vibration with a constant amplitude but is influenced by the tool motion along the thrust direction. In this paper, dynamic modeling of the cutting system is presented for the characterization of surface topography variation in UTSDC of a microlens array considering the tool-work vibration as an underdamped vibration. The natural frequency and damping ratio of the cutting system are determined by the data-dependent systems (DDS) method. Based on the analysis of the surface profile and cutting force signals, it is found that the tool-work vibration is significantly enhanced in the cut-in process when the cutting speed increases. The simulation results show that the proposed dynamic model can well-determine root-mean-squares RMS values of the surface primary profile and the dynamic force acting on the force sensor. The dynamic model provides insight into the formation of the surface topography variation in UTSDC of 3D microstructured surfaces, and the model might be applied in self-optimized machining systems in the future.

Theoretical and experimental investigation of the tool indentation effect in ultra-precision tool- servo-based diamond cutting of optical microstructured surfaces.

Ultra-precision tool-servo-based diamond cutting (UTSDC) is a promising technology for fabricating true 3-dimensional optical microstructures. The diamond tool in UTSDC moves alternatively upward and downward along the thrust direction. However, most studies on the material removal mechanism are limited to the orthogonal cutting condition where the depth of cut is invariant. The effect caused by the tool motion in the thrust direction has been overlooked. In this paper, the indentation effect affected by the tool path, tool shape and cutting speed is systematically studied. It is found that the inclined angle between the tool path direction and the main cutting direction plays a key role in the determination of the material spring back and the formation of side burr. The characteristics of indentation force and material spring back indicates that the indentation mechanism is dominant in the cut-in process where the inclined angle is large, while the shearing mechanism is dominant in the cut-out process. A new theory is proposed to explain the tool indentation mechanism in UTSDC, and the simulation results show that the theory can well predict the indentation force under various cutting conditions.

An Investigation of the Cutting Strategy for the Machining of Polar Microstructures Used in Ultra-Precision Machining Optical Precision Measurement.

In this paper, an investigation of cutting strategy is presented for the optimization of machining parameters in the ultra-precision machining of polar microstructures, which are used for optical precision measurement. The critical machining parameters affecting the surface generation and surface quality in the machining of polar microstructures are studied. Hence, the critical ranges of machining parameters have been determined through a series of cutting simulations, as well as cutting experiments. First of all, the influence of field of view (FOV) is investigated. After that, theoretical modeling of polar microstructures is built to generate the simulated surface topography of polar microstructures. A feature point detection algorithm is built for image processing of polar microstructures. Hence, an experimental investigation of the influence of cutting tool geometry, depth of cut, and groove spacing of polar microstructures was conducted. There are transition points from which the patterns of surface generation of polar microstructures vary with the machining parameters. The optimization of machining parameters and determination of the optimized cutting strategy are undertaken in the ultra-precision machining of polar microstructures.

Curvature effect on surface topography and uniform scallop height control in normal grinding of optical curved surface considering wheel vibration.

High-precision optical components with complex shapes or microstructures have been extensively used in numerous fields such as biomedicine, energy and aerospace. In order to accurately achieve the specific functions of the components, the form accuracy and uniform surface quality need to reach an ever-high level. To achieve this, ultra-precision normal grinding is used for machining various types of complex optical surfaces. However, the intricate variation of the workpiece curvature and grinding wheel vibration gives rise to great challenges to obtain higher precision and uniform surface conditions. In this study, the influence of curvature on surface topography generation has been investigated and a novel model of scallop height has been developed for surface topography generation in the normal grinding of the curved surface. In addition, the relative influence of the curvature is analyzed experimentally, in which the micro-waviness generation as a consequence of the unbalanced vibration of the grinding wheel is modeled and validated by experiments. Finally, the micro sinusoidal array with the setting value for scallop height is achieved by controlling the feed speed, which is determined by the local curvature of surface profile. The results indicated that the curvature variation posed a significant effect on surface uniformity and the model is valid to achieve surface scallop height control in the normal grinding effectively.

Fiducial-aided calibration of a displacement laser probing system for in-situ measurement of optical freeform surfaces on an ultra-precision fly-cutting machine.

Surface metrology is an essential operation to determine whether the quality of manufactured surfaces meets the design requirements. In order to improve the surface accuracy and machining efficiency in the manufacturing of optical freeform surfaces, in-situ surface measurement without re-positioning the workpiece is considered as a promising technique in advanced manufacturing. In this study, a displacement laser scanner is integrated into an ultra-precision fly-cutting machine in order to perform as a coordinate measuring machine. However, some inevitable errors such as motion errors of the machine tool, thermal drift, vibrations, and errors of the laser sensor are introduced due to the manufacturing environment. To improve the performance of the measurement system, calibration of the main error sources is investigated with consideration of the characteristics of the built laser scanner system. Hence, the relationship between the moving speed of the laser scanner and the vibration of the tested signals is studied. Following that, the errors of the z-axis scale could be corrected by measuring a four-step heights artefact. Furthermore, volumetric positioning errors are identified by the proposed modified chi-square method and Gaussian processing prediction method. Simulation and measurement experiments are conducted, and the results indicate that the calibrated measuring system can measure ultra-precision freeform surfaces with micrometre form accuracy.

Plasmonic and Superhydrophobic Self-Decontaminating N95 Respirators.

The COVID-19 pandemic is endangering the world due to the spread of respiration droplets with viruses. Medical workers and frontline staff need to wear respirators to protect themselves from breathing in the virus-containing respiration droplets. The most frequently used state-of-the-art respirators are of N95 standard; however, they lack self-decontamination capabilities. In addition, the viruses and bacteria can accumulate on the respirator surfaces, possessing high risks to the wearers over long-term usage. Photothermal decontamination is a contactless, fast, low-cost, and widely available method, capable of decontaminating the respirators. Herein, we report a plasmonic photothermal and superhydrophobic coating on N95 respirators, possessing significantly better protection than existing personal protection equipment. The plasmonic heating can raise the surface temperature to over 80 °C for this type of respirator within 1 min of sunlight illumination. The superhydrophobic features prohibit respiration droplets from accumulating on the respirator surfaces. The presence of the silver nanoparticles can provide additional protection via the silver ion's disinfection toward microbes. These synergistic features of the composite coatings provide the N95 respirator with better protection and can inspire experts from interdisciplinary fields to develop better personal protection equipment to fight the COVID-19 pandemic.