Conformal window is a protective and imaging element in the optical system of high speed flying missile. Its surfaces are required to have the ultra-precision level of surface finish and profile accuracy to ensure good imaging quality and excellent aerodynamic. The large size and high steepness of conformal window bring great challenges to the high- precision manufacturing of inside and outside surfaces. In this paper, an ultra-precision grinding process was designed for conformal window with high steepness. The problems existing in the process of machining the inner and outer surfaces of the window were analyzed, and the most suitable grinding methods for the inner and outer surfaces were determined respectively. Furthermore, the ultra-precision grinding process of conformal window were designed and verified in detail. The research of this paper can be used as a guideline for ultra-precision manufacturing of large-size optical components with high steepness.
A series of ultra-precision grinding experiments were carried out on transparent AlON ceramic. The grinding parameters (wheel speed, workpiece speed, feedrate and depth of grinding) were optimized by studying the influence of process parameters on surface quality. Comprehensive consideration of surface quality and machining efficiency, the grinding process parameters selected for finishing are as bellow: the wheel speed is 6000rpm, the workpiece speed is 39rpm, the feedrate is 5mm/min and the depth of grinding is 3μm. A grinding verification experiment was carried out after optimization. According to the optimized process parameters, the AlON optical window (the diameter is 120mm, the length-diameter ratio is 1.08, the thickness is 3mm) was processed by ultra-precision grinding. The form accuracy, surface roughness and infrared transmittance of the AlON optical window were tested and discussed.
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