Influence of tool edge waviness on the diffraction effect of diamond-turned optics: Theoretical simulation and experimental validation

In this work, the influence of tool edge waviness on the diffraction effect of diamond-turned optics is simulated theoretically and further validated experimentally. In simulation, a 3D surface topography model with consideration of the influence of tool edge waviness is established, in which the variation of tool edge profile is estimated by a linear model in relation to the cutting distance. The results show that the diffraction effect represented in simulation is consistent with the experimental observation. With the deterioration of tool edge waviness, the diffraction efficiency of the specular light decreases, but the high-order diffracted light intensively distributes in the horizontal direction on the receiving screen. Such observation can be attributed to the subgrating effect induced by the periodic duplication of the tool edge profile on the machined surface, which heavily depends on the deterioration of tool edge waviness. Finally, a waviness-controlled diamond tool is recommended to finish a diffraction-free optics by the diamond turning process. Moreover, the diffraction effect can also be employed to monitor the dynamic wear of the cutting tool in diamond turning.