Abstract
In the grinding process of large-aperture aspheric silicon carbide mirror, the wear of grinding wheel affects the surface accuracy seriously due to high hardness of silicon carbide and large diameter of aspheric mirror. Therefore, establishing surface error model of large-aperture aspheric silicon carbide mirror taking the wear of grinding wheel into account is of great significance to improve the processing quality and the imaging quality of aspheric mirror. The spiral grinding method is chosen to grind large-aperture aspheric SiC mirror in this work. The surface error of large-aperture aspheric silicon carbide mirror is established based on residual height and radial wear of grinding wheel using the grinding ratio as a bridge. The influence of grinding parameters on surface error is analyzed based on theoretical model. The results show that surface error increases with the increase of the rotation radius of workpiece and feed velocity of wheel, while it decreases with the increase of rotation velocity of workpiece and arc radius of wheel. The influence of the rotation velocity of workpiece and feed velocity of wheel is greater than that of the rotation radius of workpiece and arc radius of wheel. The regression equation of grinding ratio is established through grinding experiment, and the correlation coefficient is 0.9774 which verifies the reliability of the regression equation. Furthermore, the complete formula of surface error is acquired based on regression equation of grinding ratio. Finally, the grinding experiment of large-aperture aspheric silicon carbide mirror is carried out on the five-axis NC milling and grinding machine tool of HZ-091 type, and the error between measured value of grinding experiment and prediction value of theoretical model is less than 20%, which indicates that the theoretical model is reliable.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Kotani M, Imai T, Katayama H, Yui Y, Tange Y, Kaneda H, Enya K (2013) Quality evaluation of spaceborne SiC mirrors (II): evaluation technology for mirror accuracy using actual measurement data of samples cut out from a mirror surface. Appl Opt 52(26):6458–6466
Guo Y, Li Y, Lv B (2010) Design of new style unobscured three-mirror optical system. Acta Optical Sinica 30:1144–1147
Jiang X, Scott P, Whitehouse D (2007) Freeform surface characterization a fresh strategy. CIRP Ann-Manuf Techn 56(1):553–556
Kim B (2015) Development of aspheric surface profilometry using curvature method. Int J Precis Eng Man 16(9):1963–1968
Shimizu Y, Goto S, Lee J (2013) Fabrication of large-size SiC mirror with precision aspheric profile for artificial satellite. Precis Eng 37:640–649
Kumar RS, Shukla AK, Babu S, Sivakumar D, Gandhi AS (2011) Densification of silicon carbide using oxy-nitride additives for space-based telescope mirror applications. Opt Eng 50(7):070504–070504
Ahn K, Rhee HG, Yang HS, Kihm H (2015) Silicon carbide deformable mirror with 37 actuators for adaptive optics. J of the Korean Phys Soc 67(10):1882–1888
Shen X, Dai Y, Deng H, Guan C, Yamamura K (2013) Comparative analysis of oxidation methods of reaction-sintered silicon carbide for optimization of oxidation-assisted polishing. Opt Express 21(22):26123–26135
Jiang Z, Yin Y, Wang Q, Chen X (2016) Predictive modeling of grinding force considering wheel deformation for toric fewer-axis grinding of large complex optical mirrors. J Manuf Sci E-T ASME 138(6):061008
Xie J, Li Q, Sun J, Li Y (2015) Study on ductile-mode mirror grinding of SiC ceramic freeform surface using an elliptical torus-shaped diamond wheel. J Mater Process Tech 222:422–433
Agarwal S (2016) Optimizing machining parameters to combine high productivity with high surface integrity in grinding silicon carbide ceramics. Ceram Int 42(5):6244–6262
Zhang F, Meng B, Geng Y, Zhang Y, Li Z (2016) Friction behavior in nanoscratching of reaction bonded silicon carbide ceramic with Berkovich and sphere indenters. Tribol Int 97:21–30
Ferreira PM, Liu CR (1993) A method for estimating and compensating quasistatic errors of machine tools. J Eng Ind 115(1):149–159
Chatterjee S (1997) An assessment of quasi-static and operational errors in NC machine tools. J Manuf Syst 16(1):59–68
Lin X, Guo Y, Wang Z, Xu Q (2013) Precision model and analysis of large axisymmetric aspheric grinding. Chin J Mech Eng 49(17):65–72
Rahman MS, Saleh T, Lim HS, Son SM, Rahman M (2008) Development of an on-machine profile measurement system in ELID grinding for machining aspheric surface with software compensation. Int J Mach Tool Manu 48:887–895
Kuriyagawa T, Zahmaty MSS, Syoji K (1996) A new grinding method for aspheric ceramic mirrors. J Mater Process Tech 62(4):387–392
Xiao M, Takamura T, Takahashi S, Takamasu K (2013) Random error analysis of profile measurement of large aspheric optical surface using scanning deflectometry with rotation stage. Precis Eng 37:599–605
Xi J, Zhao H, Li B, Ren D (2016) Profile error compensation in cross-grinding mode for large-diameter aspheric mirrors. Int J Adv Manuf Technol 83:1515–1523
Lin X, Wang Z, Guo Y, Peng Y, Hu C (2014) Research on the error analysis and compensation for the precision grinding of large aspheric mirror surface. Int J Adv Manuf Technol 71(1–4):233–239
Ding K, Fu Y, Su H, Gong X, Wu K (2014) Wear of diamond grinding wheel in ultrasonic vibration-assisted grinding of silicon carbide. Int J Adv Manuf Technol 71(9–12):1929–1938
Shanawaz AM, Sundaram S, Pillai UTS, Aurtherson PB (2011) Grinding of aluminium silicon carbide metal matrix composite materials by electrolytic in-process dressing grinding. Int J Adv Manuf Technol 57(1–4):143–150
Hwang Y, Kuriyagawa T, Lee SK (2006) Wheel curve generation error of aspheric microgrinding in parallel grinding method. Int J Mach Tool Manu 46(15):1929–1933
Stephen M (2008) Grinding technology: theory and applications of machining with abrasives. Industrial Press Inc., New York
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Li, C., Zhang, F., Ma, Z. et al. Modeling and experiment of surface error for large-aperture aspheric SiC mirror based on residual height and wheel wear. Int J Adv Manuf Technol 91, 13–24 (2017). https://doi.org/10.1007/s00170-016-9753-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-9753-3