Optics and Precision Engineering, Volume. 33, Issue 5, 751(2025)

Virtual axis magnetorheological finishing of high-steepness curved optical elements

Zhiwei FU1,2, Tao ZHOU2、*, Guimei ZHANG1,2, Bingxian XIE1,2, Xing SU2, Wen HUANG2, and Kuo HAI2、*
Author Affiliations
  • 1School of Aeronautical Manufacturing and Mechanical Engineering, Nanchang Hangkong University, Nanchang330063, China
  • 2Sichuan Precision and Ultra-Precision Machining Engineering Technology Center, Chengdu61000, China
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    In response to the technological constraints of traditional magnetorheological finishing machines, which typically feature an upper-mounted polishing wheel and encounter difficulties in processing optical components with significant steepness, this study introduces a compound linkage polishing technology. This innovative approach integrates a fixed mechanical axis with a virtual axis and employs an under-mounted fixed polishing wheel. Initially, a post-processing model for the compound linkage polishing of both the mechanical and virtual axes is established, informed by the structural characteristics of the under-mounted fixed polishing wheel. The model is articulated using the Denavit-Hartenberg (DH) method and is subsequently validated through geometric analysis. The accuracy of the established post-processing model is further corroborated by conducting spot-picking experiments on a virtual shaft concave spherical surface and uniform polishing experiments on a fused silica concave spherical surface, both with a diameter of 150 mm and a radius of curvature of 150 mm. Ultimately, a concave spherical surface crafted from molten fused silica, with a diameter of 170 mm, a radius of curvature of 158 mm, and a maximum normal angle of 32.54°, is polished and refined. Experimental results indicate that the PV value of the workpiece surface, with a trimming of 5 mm, converges to 0.04λ, while the RMS value converges to 0.005λ post-modification. These findings highlight that the proposed combined polishing model of the mechanical and virtual axes provides high precision and significantly enhances the processing capabilities for high-precision, high-gradient curved optical elements. This research contributes valuable insights into the application of magnetorheological polishing technology in the fabrication of complex curved optical elements with high steepness.

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    Zhiwei FU, Tao ZHOU, Guimei ZHANG, Bingxian XIE, Xing SU, Wen HUANG, Kuo HAI. Virtual axis magnetorheological finishing of high-steepness curved optical elements[J]. Optics and Precision Engineering, 2025, 33(5): 751

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    Paper Information

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    Received: Dec. 19, 2024

    Accepted: --

    Published Online: May. 20, 2025

    The Author Email: Tao ZHOU (zhou386396@163.com)

    DOI:10.37188/OPE.20253305.0751

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