单点金刚石车削的离心变形误差修正策略  

Strategies for correction of centrifugal deformation error in single-point diamond turning

作　　者：薛志鹏 王佳宁 陈顺发 肖皓维 李明志 刘畅 张雷 李文岩 XUE Zhipeng;WANG Jianing;CHEN Shunfa;XIAO Haowei;LI Mingzhi;LIU Chang;ZHANG Lei;LI Wenyan(Chang Guang Satellite Technology Co.,Ltd.,Changchun 130000,China)

机构地区：[1]长光卫星技术股份有限公司,吉林长春130000

出　　处：《红外与激光工程》2025年第3期291-298,共8页Infrared and Laser Engineering

基　　金：吉林省科技发展计划项目(20230508149RC);吉林省重点研发项目(20220201029GX)。

摘　　要：铝合金反射镜在单点金刚石车削(Single-Point Diamond Turning, SPDT)加工过程中会因高速旋转产生离心变形,导致镜面的加工精度难以满足可见光级光学系统的质量要求。为解决上述问题,仿真分析了高速旋转状态下,反射镜表面存在的离心变形误差大小及形状,并进一步分析了离心变形对反射镜镜面加工的影响过程,提出包括镜体装夹方法以及轨迹修正方法的离心变形误差修正策略;针对300 mm口径的铝合金反射镜进行车削加工对比试验。反射镜加工精度PV=0.604λ,RMS=0.084λ,相较传统加工方案,RMS值和PV值分别降低了56.02%和58.88%,从而验证了所提出的离心变形误差修正策略能有效控制离心变形形状并实现误差的高效修正,为反射镜高精度加工提供了理论依据和技术支持。Objective Due to the high rotational speed,aluminium alloy mirrors are centrifugally deformed during singlepoint diamond turning(SPDT)machining,resulting in mirror surfaces not meeting the stringent accuracy specifications required for optical systems in the visible spectrum.The core of centrifugal deformation suppression is to solve the problem of mirror deformation caused by centrifugal force during processing.The purpose of this study is to ensure that the mirror has higher surface shape accuracy by suppressing centrifugal deformation,so as to improve the imaging quality of the optical system and make the image clearer and more accurate.Methods To mitigate this issue,a computational simulation was conducted to quantify and characterize the centrifugal deformational errors present on the reflector surface under conditions of elevated rotational speeds.Additionally,an in-depth analysis was performed to elucidate the impact of centrifugal deformation on the mirror surface fabrication.A corrective approach for centrifugal deformational errors was developed,encompassing advanced fixturing techniques for the mirror body and path optimization algorithms for trajectory correction.An experimental study was carried out on a 300 mm aperture aluminum alloy reflector to benchmark the machining precision.Results and Discussions A clamping process considering centrifugal deformation error compensation was designed to ensure the rotational symmetry of the mirror deformation(Fig.5).According to the turning process of the rotary symmetrical parts(Fig.6),a trajectory generation method to correct the centrifugal deformation error was designed(Fig.7).Test reflector achieved a peak-to-valley(PV)value of 0.604λand a root mean square(RMS)value of 0.084λ(Fig.8),representing a significant improvement of 56.02%and 58.88%reduction in RMS and PV,respectively,over conventional machining protocols.Conclusions This research validates the efficacy of the proposed corrective strategy in managing centrifugal deformational geometry and effectu

关 键 词：单点金刚石车削 离心变形 误差补偿 光学制造 

分 类 号：TH161.1[机械工程—机械制造及自动化]