Modeling of the new machining methods for ultra-precision axisymmetric aspheric mirrors

A new form generation method for ultra-precision axisymmetric aspheric mirrors is introduced. Linear motion guides are employed in the feed systems of most diamond turning machines. For rotary axes can be made less expensive, easier and more compact than a linear guide at the same precision level, a rotary arm that carries a diamond tool combined with a fast tool servo are used to replace the straight lines. The micro linear feed of the fast tool servo is real-time calculated with the use high resolution angular feedback on the swing tool based on the aspheric equation. Synchronized motion of the fast tool servo, workpiece and the diamond tool produces ultra-precision axisymmetric aspheric mirrors. Geometric models of cutting tool path, the motion of fast tool servo and the corresponding calculations are presented. The machining approach is verified to be simple and reliable by computer simulation, so the production efficiency can be improved and the equipment input can be reduced.