Papers by Author: Hao Huang

Abstract: According to needs of aspheric lens grinding and measurement with X/Y/Z 3-axis grinding machines, a CAM system is designed and implemented. The system, based on the parallel grinding geometry model, has realized the function of grinding locus planning, form error compensation, NC program auto-generation, on-machine measurement, grinding wheel on-machine measurement, simulation and technical database. To verify the stability of this CAM system, experiments were performed with three independent machining experiments. The experimental results indicate that the system realized the whole process of aspheric grinding, and it improved the machining efficiency and automation. Especially, this system adopted on-machine form error compensation technology and improved the machining accuracy. By implementing the error compensation integrated in the CAM system, the surface form error of a 430mm×430mm aspheric lens is decreased from PV8.2µm to PV4.1µm. The grinding accuracy was improved 100%.

Abstract: The causes of machining errors are very complicated and apt to mutual influence in aspheric grinding, so it is difficult to improve machining accuracy by control one cause. To compensate the machining error of large aspheric grinding, an error-compensation technique using on-machine profile measurement system in three axes grinding machine are presented. To verify the effectiveness of the compensation machining and the reliability of the measurement system, experiments on high-precision grinding machine were performed. Moreover, the compensation machining with the on-machine measurement substantially decreases the machining errors and improve machining accuracy by more than 45%, compared with the non-compensation machining.

Abstract: In the traditional precision machining, it is easy to introduce positioning error because of the separation of the machining and the measurement. In order to solve this problem, an online measurement technique for aspheric grinding has been put forward. It measured the workpiece with sensor which was fixed to the high-precision machine tool. It processed data with the algorithm of Two-dimensional weighted average filtering and curve fitting based on Gauss-Newton and Levenberg-Marquardt least-square method. The experimental results indicated that the fitting residual error was less than 3×10-6 mm. In the grinding process, the measurement error was of the order of the magnitude of 10-3 mm. It can be concluded that the technique measures the surface exactly, and improves the machining accuracy effectively by providing accurate data for compensation.

Abstract: Ultra precision grinding is currently the main technology for large scale advanced optical lens machining. In this paper, the machining system of ultra precision surface grinder is investigated. The experiments of new wedged aspheric lens with the dimension of 430*430mm have been conducted by SD600 diamond wheel, and the parallel grinding, cup truing and on-machine measuring are used for good accuracy. The results show the effective machining system and the problem for next research.