A Study on Manufacturing Process of High-speed Rotating Reflector
Date Issued
2008
Date
2008
Author(s)
Chang, Je-Yuan
Abstract
In recent years, specifications of optical elements are getting stringent. It’s crucial to plan an effective fabrication process to ensure their engineering functionalities. Based on the functional requirements and service environment, optical reflectors must go through a series of manufacturing processes including material selection, forming, precision manufacturing, super-finishing and coating. In these processes, precision manufacturing is the key to the accuarcy of reflectors.n this thesis, optical reflectors were designed to be used in high-speed rotating environment. Al 6061 was selected for the reflector to run in high rotation speeds of minimum 30,000 rpm. The specifications require flatness P-V of facets on reflector less than . In order to obtain perfectly flat surface, mechanical chemical polishing (MCP) and single-point diamond turning (SPDT) are used in the fabrication process plan and comparisons are made for the end results. Final measurement gives a result of flatness P-V by polishing of about , while that by diamond turning of . To get more reflectivity, Al layer coated on electroless Nickel as combination material is selected for light of specific wavelength in experiments.urther, testing whole system proves that the reflector rotation speed can reach 30,000 rpm as required. In the testng, the displacement of reflective light is observed and measured. It is found that spindle wobbling and substrate deformation remian as key issues. Further study is made by simulation and the model of deformation is established and analyzed. he present study shows that diamond turning process can best make reflector flatness within specification, but some defects on surface remain. Therefore, fabrication processes shall be further investigated in future work for the improvement of reflectors quality.
Subjects
reflector
high-speed rotation
MCP
SPDT
Type
thesis
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