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Results for “computer-controlled optical surfacing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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17 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Statistical Tool Size Study for Computer-Controlled Optical Surfacing

Over the past few decades, computer-controlled optical surfacing (CCOS) systems have become more deterministic. A target surface profile can be predictably achieved with a combination of tools of different sizes. However, deciding the optimal set of tool sizes that will achieve the target residual error in the shortest run time is difficult, and no general guidance has been proposed in the literature. In this paper, we present a computer-assisted study on choosing the proper tool size for a given surface error map. First, we propose that the characteristic frequency ratio (CFR) can be used as a general measure of the correction capability of a tool over a surface map. Second, the performance of different CFRs is quantitatively studied with a computer simulation by applying them to guide the tool size selection for polishing a large number of randomly generated surface maps with similar initial spatial frequencies and root mean square errors. Finally, we find that CFR = 0.75 achieves the most stable trade-off between the total run time and the number of iterations and thus can be used as a general criterion in tool size selection for CCOS processes. To the best of our knowledge, the CFR is the first criterion that ties tool size selection to overall efficiency.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A comprehensive review of dwell time optimization methods in computer-controlled optical surfacing

Dwell time plays a vital role in determining the accuracy and convergence of the computer-controlled optical surfacing process. However, optimizing dwell time presents a challenge due to its ill-posed nature, resulting in non-unique solutions. To address this issue, several well-known methods have emerged, including the iterative, Bayesian, Fourier transform, and matrix-form methods. Despite their independent development, these methods share common objectives, such as minimizing residual errors, ensuring dwell time's positivity and smoothness, minimizing total processing time, and enabling flexible dwell positions. This paper aims to comprehensively review the existing dwell time optimization methods, explore their interrelationships, provide insights for their effective implementations, evaluate their performances, and ultimately propose a unified dwell time optimization methodology.

36 MATERIALS SCIENCE↗
DOE OSTI2025

CUDO: closed-form universal dwell-time optimization for computer-controlled optical surfacing

Precision optical figuring demands fast and accurate dwell time optimization to reach nanometer- and sub-nanometer-level accuracy in next-generation optical systems. We introduce CUDO (closed-form universal dwell-time optimization), the first, to the best of our knowledge, unified closed-form analytical framework that supports both function-form and matrix-form dwell time models in computer-controlled optical surfacing (CCOS). In contrast to traditional methods, which rely on iterative optimization and hyperparameter tuning, our framework derives direct analytical solutions with no adjustable parameters. This approach unifies the solution principles of existing methods within a single mathematical model, delivering three key advantages: (1) accuracy on par with, or superior to, iterative solvers, (2) substantial reduction in computation time, and (3) numerical robustness. Comparative studies with prior art confirm that closed-form solutions achieve equivalent residual error while removing runtime bottlenecks. By simplifying the implementation and enabling real-time, scalable deployment, CUDO establishes a practical foundation for future deterministic fabrication of large-aperture and high-performance optics.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Masks For Deposition Of Aspherical Optical Surfaces

Masks of improved design developed for use in fabrication of aspherical, rotationally symmetrical surfaces of mirrors, lenses, and lens molds by evaporative deposition onto rotating substrates. In deposition chamber, source and mask aligned with axis of rotation of substrate. Mask shadows source of rotating substrate. Azimuthal opening (as function of radius) in mask proportional to desired thickness (as function of radius) to which material deposited on substrate. Combination of improved masks and modern coating chambers provides optical surfaces comparable or superior to those produced by conventional polishing, computer-controlled polishing, replication from polished molds, and diamond turning, at less cost in material, labor, and capital expense.

Rogers, John R.↗
DOE OSTI2024

E-PVT: enhanced position-velocity-time scheduler for computer-controlled optical finishing with comprehensive considerations of dynamics constraints, continuity and efficiency

Deterministic computer-controlled optical finishing is an essential approach for achieving high-quality optical surfaces. Its determinism and convergence rely heavily on precise and smooth motion control to guide the machine tool over an optical surface to correct residual errors. One widely supported and smooth motion control model is position-velocity-time (PVT), which employs piecewise cubic polynomials to describe positions. Our prior research introduced a PVT-based velocity scheduling method, demonstrating sub-nanometer level convergence in ion beam figuring (IBF) processes. However, three challenges remained. Firstly, this method relies on quadratic programming, resulting in computational intensiveness for dense tool paths. Secondly, the dynamics constraints and velocity and acceleration continuities are not comprehensively considered, limiting the full potential of PVT-based control. Thirdly, no compensation mechanism existed when dynamics constraints are exceeded. In this study, in response to these challenges, we proposed the Enhanced PVT (E-PVT) method, reducing the time complexity from O ( n 3 ) to O ( n ) while fully addressing dynamics constraints and continuities. A novel compensation method utilizing particle swarm optimization was proposed to address situations where dynamics constraints might be exceeded while maintaining the overall processing efficiency. Validation through simulation and experimentation confirmed the improved performance of E-PVT.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Fast, accurate rangefinder

Computer-controlled optical ranging system detects objects as close as 1m and as distant as 30m. Originally developed for robot planetary-surface exploration, system is applicable to vehicular obstacle avoidance, surveying, remote manipulator operation, and other applications.

Johnston, A. R.↗
NASA NTRS2015

The Development of a Deflectometer for Accurate Surface Figure Metrology

Marshall Space Flight Center is developing the method of direct fabrication for high resolution full-shell x-ray optics. In this technique the x-ray optics axial profiles are figured and polished using a computer-controlled ZeekoIRP600X polishing machine. Based on the Chandra optics fabrication history about one third of the manufacturing time is spent on moving a mirror between fabrication and metrology sites, reinstallation and alignment with either the metrology or fabrication instruments. Also, the accuracy of the alignment significantly affects the ultimate accuracy of the resulting mirrors. In order to achieve higher convergence rate it is highly desirable to have a metrology technique capable of in situ surface figure measurements of the optics under fabrication, so the overall fabrication costs would be greatly reduced while removing the surface errors due to the re-alignment necessary after each metrology cycle during the fabrication. The goal of this feasibility study is to demonstrate if the Phase Measuring Deflectometry can be applied for in situ metrology of full shell x-ray optics. Examples of the full-shell mirror substrates suitable for the direct fabrication

X-ray optics metrology↗
NASA NTRS1996

Sensing Position With Approximately Constant Contact Force

Computer-controlled electromechanical system uses number of linear variable-differential transformers (LVDTs) to measure axial positions of selected points on surface of lens, mirror, or other precise optical component with high finish. Pressures applied to pneumatically driven LVDTs adjusted to maintain small, approximately constant contact forces as positions of LVDT tips vary.

Sturdevant, Jay↗
NASA NTRS1986

Proposed method of producing large optical mirrors Single-point diamond crushing followed by polishing with a small-area tool

Faster production of large optical mirrors may result from combining single-point diamond crushing of the glass with polishing using a small area tool to smooth the surface and remove the damaged layer. Diamond crushing allows a surface contour accurate to 0.5 microns to be generated, and the small area computer-controlled polishing tool allows the surface roughness to be removed without destroying the initial contour. Final contours with an accuracy of 0.04 microns have been achieved.

Wright, G.↗
NASA NTRS2006

NASA Tech Briefs, July 2006

Topics covered include: Airport Remote Tower Sensor Systems; Implantable Wireless MEMS Sensors for Medical Uses; Embedded Sensors for Measuring Surface Regression; Coordinating an Autonomous Earth-Observing Sensorweb; Range-Measuring Video Sensors; Stability Enhancement of Polymeric Sensing Films Using Fillers; Sensors for Using Times of Flight to Measure Flow Velocities; Receiver Would Control Phasing of a Phased-Array Antenna; Modern Design of Resonant Edge-Slot Array Antennas; Carbon-Nanotube Schottky Diodes; Simplified Optics and Controls for Laser Communications; Coherent Detection of High-Rate Optical PPM Signals; Multichannel Phase and Power Detector; Using Satellite Data in Weather Forecasting: I; Using Dissimilarity Metrics to Identify Interesting Designs; X-Windows PVT Widget Class; Shuttle Data Center File-Processing Tool in Java; Statistical Evaluation of Utilization of the ISS; Nanotube Dispersions Made With Charged Surfactant; Aerogels for Thermal Insulation of Thermoelectric Devices; Low-Density, Creep-Resistant Single-Crystal Superalloys; Excitations for Rapidly Estimating Flight-Control Parameters; Estimation of Stability and Control Derivatives of an F-15; Tool for Coupling a Torque Wrench to a Round Cable Connector; Ultrasonically Actuated Tools for Abrading Rock Surfaces; Active Struts With Variable Spring Stiffness and Damping; Multiaxis, Lightweight, Computer-Controlled Exercise System; Dehydrating and Sterilizing Wastes Using Supercritical CO2; Alpha-Voltaic Sources Using Liquid Ga as Conversion Medium; Ice-Borehole Probe; Alpha-Voltaic Sources Using Diamond as Conversion Medium; White-Light Whispering-Gallery-Mode Optical Resonators; Controlling Attitude of a Solar-Sail Spacecraft Using Vanes; and Wire-Mesh-Based Sorber for Removing Contaminants from Air.

Source record↗
NASA NTRS2010

Design Considerations of Polishing Lap for Computer-Controlled Cylindrical Polishing Process

The future X-ray observatory missions, such as International X-ray Observatory, require grazing incidence replicated optics of extremely large collecting area (3 m2) in combination with angular resolution of less than 5 arcsec half-power diameter. The resolution of a mirror shell depends ultimately on the quality of the cylindrical mandrels from which they are being replicated. Mid-spatial-frequency axial figure error is a dominant contributor in the error budget of the mandrel. This paper presents our efforts to develop a deterministic cylindrical polishing process in order to keep the mid-spatial-frequency axial figure errors to a minimum. Simulation studies have been performed to optimize the operational parameters as well as the polishing lap configuration. Furthermore, depending upon the surface error profile, a model for localized polishing based on dwell time approach is developed. Using the inputs from the mathematical model, a mandrel, having conical approximated Wolter-1 geometry, has been polished on a newly developed computer-controlled cylindrical polishing machine. We report our first experimental results and discuss plans for further improvements in the polishing process.

Khan, Gufran S.↗
NASA NTRS2010

Computer-Controlled Cylindrical Polishing Process for Large X-Ray Mirror Mandrels

We are developing high-energy grazing incidence shell optics for hard-x-ray telescopes. The resolution of a mirror shells depends on the quality of cylindrical mandrel from which they are being replicated. Mid-spatial-frequency axial figure error is a dominant contributor in the error budget of the mandrel. This paper presents our efforts to develop a deterministic cylindrical polishing process in order to keep the mid-spatial-frequency axial figure errors to a minimum. Simulation software is developed to model the residual surface figure errors of a mandrel due to the polishing process parameters and the tools used, as well as to compute the optical performance of the optics. The study carried out using the developed software was focused on establishing a relationship between the polishing process parameters and the mid-spatial-frequency error generation. The process parameters modeled are the speeds of the lap and the mandrel, the tool s influence function, the contour path (dwell) of the tools, their shape and the distribution of the tools on the polishing lap. Using the inputs from the mathematical model, a mandrel having conical approximated Wolter-1 geometry, has been polished on a newly developed computer-controlled cylindrical polishing machine. The preliminary results of a series of polishing experiments demonstrate a qualitative agreement with the developed model. We report our first experimental results and discuss plans for further improvements in the polishing process. The ability to simulate the polishing process is critical to optimize the polishing process, improve the mandrel quality and significantly reduce the cost of mandrel production

Khan, Gufran S.↗
NASA NTRS2009

Development of a Computer-Controlled Polishing Process for X-Ray Optics

The future X-ray observatory missions require grazing-incidence x-ray optics with angular resolution of < 5 arcsec half-power diameter. The achievable resolution depends ultimately on the quality of polished mandrels from which the shells are replicated. With an aim to fabricate better shells, and reduce the cost/time of mandrel production, a computer-controlled polishing machine is developed for deterministic and localized polishing of mandrels. Cylindrical polishing software is also developed that predicts the surface residual errors under a given set of operating parameters and lap configuration. Design considerations of the polishing lap are discussed and the effects of nonconformance of the lap and the mandrel are presented.

Khan, Gufran S.↗
NASA NTRS1993

Magneto-optic superlattice thin films: Fabrication, structural and magnetic characterization

During this quarter studies were extended to determine the electronic contribution to the perpendicular interface anisotropy in Co-based multilayers. Using in situ Kerr effect measurements, the influences of different transition metals (TM = Ag, Au, Cu, and Pd) on the magnetic properties of single-crystal Co films grown on Pd (111) and Au (111) surfaces are investigated. Last quarter the discovery of a large peak in the perpendicular anisotropy when approximately one monolayer of Cu or Ag is deposited on the Co surface was reported. We now have added a computer-controlled stepper-motor drive to our MBE sample transfer mechanism. The motor allows us to move the sample at a constant velocity from behind a shutter during deposition. The film, therefore, is deposited as a wedge with a linear variation of thickness across the substrate. In this way, a continuous range of coverage on a single sample is studied. The stepper motor also provides the necessary control for precisely positioning the sample in the laser beam for Kerr effect measurements at the different coverages.

Falco, C. M.↗
NASA NTRS1986

The soft X-ray/EUV calibration facility at the University of Colorado

The components of the calibration facility at the University of Colorado are described. The system is capable of analyzing the performance of optical components in the wavelength range from 2.7 to 2500 A. The system uses two light sources: a water-cooled hollow cathode gas discharge source and a soft X-ray source. The 2.2-m grazing incidence monochrometer, slits, large chamber, and computer-controlled manipulator are examined. The NBS aluminum oxide photodiode, a flowing gas proportional counter, and an imaging microchannel plate device are employed to detect the light. The optics, detectors, and data acquisition system are computer controlled. The facility is applicable for evaluating the performance of diffraction gratings, multilayer mirrors, reflective coatings, spectrographs, surface roughness scattering, and absolute detector efficiencies. Examples demonstrating the capabilities of the facility and a diagram of the facility are presented.

Windt, David L.↗
NASA NTRS2008

Single-Mode WGM Resonators Fabricated by Diamond Turning

A diamond turning process has made possible a significant advance in the art of whispering-gallery-mode (WGM) optical resonators. By use of this process, it is possible to fashion crystalline materials into WGM resonators that have ultrahigh resonance quality factors (high Q values), are compact (ranging in size from millimeters down to tens of microns), and support single electromagnetic modes. This development combines and extends the developments reported in "Few- Mode Whispering-Gallery-Mode Resonators" (NPO-41256), NASA Tech Briefs, Vol. 30, No. 1 (January 2006), page 16a and "Fabrication of Submillimeter Axisymmetric Optical Components" (NPO-42056), NASA Tech Briefs, Vol. 31, No. 5 (May 2007), page 10a. To recapitulate from the first cited prior article: A WGM resonator of this special type consists of a rod, made of a suitable transparent material, from which protrudes a thin circumferential belt of the same material. The belt is integral with the rest of the rod and acts as a circumferential waveguide. If the depth and width of the belt are made appropriately small, then the belt acts as though it were the core of a single-mode optical fiber: the belt and the rod material adjacent to it support a single, circumferentially propagating mode or family of modes. To recapitulate from the second cited prior article: A major step in the fabrication of a WGM resonator of this special type is diamond turning or computer numerically controlled machining of a rod of a suitable transparent crystalline material on an ultrahigh-precision lathe. During the rotation of a spindle in which the rod is mounted, a diamond tool is used to cut the rod. A computer program is used to control stepping motors that move the diamond tool, thereby controlling the shape cut by the tool. Because the shape can be controlled via software, it is possible to choose a shape designed to optimize a resonator spectrum, including, if desired, to limit the resonator to supporting a single mode. After diamond turning, a resonator can be polished to increase its Q. By virtue of its largely automated, computer-controlled nature, the process is suitable for mass production of nominally identical single-mode WGM resonators. In a demonstration of the capabilities afforded by this development, a number of WGM resonators of various designs were fabricated side by side on the surface of a single CaF2 rod (see figure).

Grudinin, Ivan↗
NASA NTRS2005

Advanced Three-Dimensional Display System

A desktop-scale, computer-controlled display system, initially developed for NASA and now known as the VolumeViewer(TradeMark), generates three-dimensional (3D) images of 3D objects in a display volume. This system differs fundamentally from stereoscopic and holographic display systems: The images generated by this system are truly 3D in that they can be viewed from almost any angle, without the aid of special eyeglasses. It is possible to walk around the system while gazing at its display volume to see a displayed object from a changing perspective, and multiple observers standing at different positions around the display can view the object simultaneously from their individual perspectives, as though the displayed object were a real 3D object. At the time of writing this article, only partial information on the design and principle of operation of the system was available. It is known that the system includes a high-speed, silicon-backplane, ferroelectric-liquid-crystal spatial light modulator (SLM), multiple high-power lasers for projecting images in multiple colors, a rotating helix that serves as a moving screen for displaying voxels [volume cells or volume elements, in analogy to pixels (picture cells or picture elements) in two-dimensional (2D) images], and a host computer. The rotating helix and its motor drive are the only moving parts. Under control by the host computer, a stream of 2D image patterns is generated on the SLM and projected through optics onto the surface of the rotating helix. The system utilizes a parallel pixel/voxel-addressing scheme: All the pixels of the 2D pattern on the SLM are addressed simultaneously by laser beams. This parallel addressing scheme overcomes the difficulty of achieving both high resolution and a high frame rate in a raster scanning or serial addressing scheme. It has been reported that the structure of the system is simple and easy to build, that the optical design and alignment are not difficult, and that the system can be built by use of commercial off-the-shelf products. A prototype of the system displays an image of 1,024 by 768 by 170 (=133,693,440) voxels. In future designs, the resolution could be increased. The maximum number of voxels that can be generated depends upon the spatial resolution of SLM and the speed of rotation of the helix. For example, one could use an available SLM that has 1,024 by 1,024 pixels. Incidentally, this SLM is capable of operation at a switching speed of 300,000 frames per second. Implementation of full-color displays in future versions of the system would be straightforward: One could use three SLMs for red, green, and blue, respectively, and the colors of the voxels could be automatically controlled. An optically simpler alternative would be to use a single red/green/ blue light projector and synchronize the projection of each color with the generation of patterns for that color on a single SLM.

Geng, Jason↗