Development Of Sotfware Platform For Ultra-Precision Machining Of Freeform Optical Surfaces

The application of optical free-form surface in an optical system can simplify thestructure of the system, improve the optical performance of the system, and enhancethe flexibility of the optical design. In the design and manufacture of the free-formoptical surface parts, in order to obtain the best solution of the free-form opticalsurface processing and how to do the machinability evaluation for the free-formoptical surface, relying on the existing design methods can not meet the requirements.This thesis is dedicated to the research and development of the software for theoptical free-form surface machining, to obtain the best solution for the free-formoptical surface processing, and provide the function of machinability evaluation forthe free-form optical surface. This thesis focuses on the following work:(1)The overall framework of the software platform is designed, which lays agood foundation for the development of the subsequent software. According to thespecification of software design, the software is divided into the hierarchy of themodule by function, each module corresponding to the functional requirements of thesoftware, meanwhile identifying the calling relationships between modules.According to the functional requirements of the software,this software consists of theoptical free-form surface design module, the tool path generation module, the CNCcode generation and verification module, the surface morphology generation andevaluation module,the error analysis and compensation module, and the opticalperformance analysis module.The software runs by calling the six modules in turn.(2)The classes to each object of the software are designed. According to theanalysis of software features and the situation of the actual processing, the objectswhose classes need to be designed are determined in this software, such as machinetools, cutting tools, free-form surface, etc. According to the design principles of class,Open-Closed Principle, Single Responsibility Principle, Interface SegregationPrinciple, Liskov Substitution Principle and other design principles, the structure of the classes is designed, and the calling relationships between classes are determined.(3)The auxiliary functions of the software are designed. This software requiresthe NC simulation for the processing, large amounts of data needs to be stored, andthe data files of the products need to be read. In this thesis,the simulation views arecreated by using the OpenGL,and the solid models in this software are establishedwith the combination of Z-map model and the B-rep model in this process; thedatabase storage model of this software is designed using the SQL Server database; inthe reading process of the IGES files, the data structure of the solid model is designed,which realizes the reading of the solid model of the surface.(4)In the processing program of the free-form optical surface, the algorithms ofthe tool path, the surface morphology and the error analysis are presented for the FTSprocessing. According to the processing characteristics of FTS,the CNC codegeneration and validation module is designed. This module can not onlyautomatically generate CNC code according to the tool path and other machiningparameters, but also can import and verify CNC code from outside, and simulate themachining according to the CNC code.