Simulation of Optical Surface errors Resulting from Manufacturing Process

The work proposed here is to develop and demonstrate software that provides a simulation of optical surface errors produced during manufacturing processes that use tubular grinding. The softwae will be designed with refernece to the Opticam SM and SX precision grinding machines. The tubular grinding process used in the Opticam machines is a deterministic method that promises to enable concurrent engineering of optical elements in an agile manufacturing environment. Unlike conventional optical manufacturing processes that require extensive hand work, Opticam technology produces optical surfaces having shapes that are accurately determined by the geometry of the grinding machine. Surface errors produced during tubular grinding are closely related to the relative alignment of the tool and workpiece. This makes it possible to predict the errors produced by various types of misalignment, and thereby make it possible to correct the alignment of the machine by inspecting a manufactured part. In Phase I, we will develop and demontsrate prototype software for predicting such surface errors, formulate the concpet of interfacing to commericlaly available optical design software, and formulate the concept for making the software an integral part of the Opticam manufacturing process.