Single-Point Turning Point of Polycrystalline Alumina Missile Domes

Conformal Optics is becoming increasingly important for military applications. New manufacturing methods are being developed through university, government and industry efforts. Unique finishing approaches are being investigated, some with more success than others, and each with specific limitations to overcome. Single Point Turning of materials such as ALON and Polycrystalline Alumina is being considered in this proposal request which to date has shown very limited success. Contour grinding with a wheel or ball shaped diamond tool in conjuntion with our unique Ultra-Finishing process could in fact be a more viable solution. Instead of a single point following the contour we use a "single spot" that is produced with our unique Ultraform Tool designs. Materials such as Polycrystalline Alumina with finer grain structures, ALON, Sapphire, Spinel, deep concave surfaces, and mid spatial frequencies all render the existing finishing processes inadequate. This proposal will present the feasibility of applying a unique process for the Ultra Finishing of Optics referred to herein as UFO. Research in the area of new generation II compliant finishing tools utilizing a pressurized belt/wheel concept in conjunction with single spot, removal functions, machine configuration, and optimized tool paths will be the key task areas of investigation.