Optimal D-Shaped Toolpath Design for Minimizing X-Axis Servo Following Error in Turning the Off-Axis Optical Surfaces.

Baohua Chen, Quanying Wu, Yunhai Tang, Fei Wang, Junliu Fan, Xiaoyi Chen, Haomo Yu, Yi Sun

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Article in Materials (Basel, Switzerland), 2025. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.

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8 authors.

Baohua ChenKey Laboratory of Efficient Low-Carbon Energy Conversion and Utilization of Jiangsu Provincial Higher Education Institutions, School of Physical Science and Technology, Suzhou University of Science and Technology, Suzhou 215009, China.

Quanying WuKey Laboratory of Efficient Low-Carbon Energy Conversion and Utilization of Jiangsu Provincial Higher Education Institutions, School of Physical Science and Technology, Suzhou University of Science and Technology, Suzhou 215009, China.

Yunhai TangKey Laboratory of Efficient Low-Carbon Energy Conversion and Utilization of Jiangsu Provincial Higher Education Institutions, School of Physical Science and Technology, Suzhou University of Science and Technology, Suzhou 215009, China.

Fei WangComputing Science and Artificial Intelligence College, Suzhou City University, Suzhou 215104, China.ORCID 0009-0007-9455-6884

Junliu FanKey Laboratory of Efficient Low-Carbon Energy Conversion and Utilization of Jiangsu Provincial Higher Education Institutions, School of Physical Science and Technology, Suzhou University of Science and Technology, Suzhou 215009, China.

Xiaoyi ChenSuzhou Mason Optical Co., Ltd., Suzhou 215127, China.

Haomo YuSuzhou Mason Optical Co., Ltd., Suzhou 215127, China.

Yi SunSuzhou Mason Optical Co., Ltd., Suzhou 215127, China.

Funding

Graduate Research and Innovation Projects of Jiangsu Province KYCX243429Jiangsu Province '14th Five-Year Plan' key discipline Project 2021135National Natural Science Foundation of China 62275187, 62375196, 61875145Suzhou Industrial Foresight and Key Core Technology Project SYC2022145Suzhou Key Laboratory of Optical Precision Testing Technology SZS201202The Natural Science Foundation of the Jiangsu Higher Education Institutions of China 22KJA140002

6 · The paper itself

Abstract

In the slow tool servo (STS) turning technology for optical lenses, the D-shaped toolpath can improve the quality of the optical surfaces of off-axis aspheric and cylindrical microlens arrays. However, the traditional D-shaped toolpath has the problem of excessive servo following error in the X-axis. To address this issue, the projection of the D-shaped toolpath in the XZ plane is divided into a cutting zone and a transition zone. In the transition zone, an equation system based on continuity constraints (surface height, feed-rate, acceleration) is established. By solving this system of equations, a toolpath can be obtained along which the feed-rate of the X-axis varies smoothly. An example shows that the acceleration of the X-axis of the lathe is reduced by 84% compared to the traditional D-shaped toolpath. In the XZC interpolation mode, the spindle velocity of the C-axis changes smoothly. An off-axis spherical surface and an integral mirror have been machined using the optimized D-shaped toolpath. The X-axis servo following error of the lathe during processing is within 7 nm, and the surface shape accuracy reaches 0.361λ at 632.8 nm. This method enables high-precision processing of off-axis curved surfaces and cylindrical arrays.

Indexed as

D-shaped toolpathhigh-precision turningservo following errorslow tool servo

Identifiers

PMID41010187

DOI10.3390/ma18184343

PMCPMC12471532

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