Fabrication of free-form surfaces that are frequently demanded for the construction of optical imaging systems is described. To obtain a tool motion with large amplitude and high bandwidth, a novel long-stroke fast tool servo is proposed and installed on the Z-axis of a diamond turning machine as an additional synchronized axis. In addition, a special on-machine measurement device is used to measure the optical parameters of the machined surface and to compensate for the residual form of errors that are commonly produced in the diamond turning process. Actual machining test results show that the proposed procedures are capable of generating the copper free-form mirrors of 50mm diameter to a form accuracy of 0.15μm in peak-to-valley value error.
Financed by the National Centre for Research and Development under grant No. SP/I/1/77065/10 by the strategic scientific research and experimental development program:
SYNAT - “Interdisciplinary System for Interactive Scientific and Scientific-Technical Information”.