Multi Tool Concept. Matthias Pfaff, Roland Mandler, Sebastian Stoebenau OptoTech Optikmaschinen GmbH. APOMA Fall Workshop 2016

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1 Multi Tool Concept Matthias Pfaff, Roland Mandler, Sebastian Stoebenau OptoTech Optikmaschinen GmbH APOMA Fall Workshop 2016 Tucson, AZ, USA /11

2 Content Introduction OptoTech Motivation Grinding Technology Multi Tool Polishing Technology Membrane Polishing FEM-Tool Advanced Wheel Polishing Technology A-WPT Active Fluid Jet Polishing A-FJP Sub-Aperture Pitch Polishing Pitch Polishing SynchroSpeed Polishing

3 OptoTech Found 1985 by Roland Mandler 250 employees at 8 sites worldwide Equipment for precision optics (60%), ophthalmics (30%) and coating (10%) Export ratio of >85%

4 OptoTech (2) Precision Optics Metrology Ophthalmics Coating Tooling Consumables

5 OptoTech (3) Worldwide Presence: Wettenberg Jena Germantown, WI (USA) Palm, PA (USA) Bellach (Switzerland) Milan (Italy) Mumbai (India) Hong Kong OptoTech Subsidiaries Sales- and Service-Agencies

6 Motivation Big mix of geometries, machine kinematics and tools used in prior processing steps (grinding, prepolishing) They all have an influence on the following polishing and correction technologies. There is no one tool fits all, especially on asphere and free form processing

7 Spherical Grinding Technology Spherical Grinding Cup wheels Circular tool contact Smoothing effect of line contact Improved by 3C Technology

contact One time touch of tool and workpiece z 1

8 Aspherical Grinding Technology Aspherical and Free Form Grinding Peripheral wheels Single point contact One time touch of tool and workpiece z 1 cy 2 1 (1 k) c 2 y 2 A 4 y 4 A 6 y 6 A 8 y 8 A 10 y 10...

9 Consequence Every geometry and every error type requires different handling on the follow-up process Ergo: we do require various polishing concepts with a high freedom of tooling and machine kinematics OptoTech MultiTool Concept

10 MultiTool Spherical and Plano Surfaces SynchroSpeed Polishing Pitch Polishing Aspherical and FreeForm Surfaces FEM Membrane Polishing A-WPT Advanced Wheel Polishing Technology A-FJP Active Fluid Jet Polishing Fine Correction and Smoothing As above, plus Sub Aperture Pitch Polishing

11 SynchroSpeed Polishing Development of abrasion-optimised tools Kinematics Machines concepts Basics Since 1965: Erhard Brück (Leitz, Wetzlar) Since 1974: Erhard Brück (Loh, Wetzlar) Improvements and optimisations Since 1985: Roland Mandler (OptoTech)

12 SynchroSpeed in a nutshell Projection of the glass surface into the tool Considering relative speed and radius r lens = r tool = const r(t) = 0 Radius f(t) C/T = f(t) n1 cos rel const. n 2

SynchroSpeed and Pitch Polishing SynchroSpeed Polishing Fast and relatively inexpensive tool set Very flexible and well suited for small batches

13 SynchroSpeed and Pitch Polishing SynchroSpeed Polishing Fast and relatively inexpensive tool set Very flexible and well suited for small batches Surface roughness higher than pitch Pitch Polishing Very slow and expensive tool set (incl. auxiliaries) Not flexible at all Excellent surface roughness

14 SynchroSpeed Polishing Polishing of plano optics and spheres using large-area tools: SynchroSpeed technology Established process with high removal rates and low-frequency residuals

0,2 µm within 80 min Improved correction convergence using POLyCAM 3D by a

15 FEM Membrane Polishing Tool Polishing of plano optics, spheres and aspheres using sub-aperture tools: Membrane Tool Technology Processed sample: asphere Ø 50 mm, PV < 0,2 µm within 80 min Improved correction convergence using POLyCAM 3D by a userdefined active polishing spot diameter that is automatically kept constant across the surface!

A-WPT Advanced Wheel Polishing Technology Polishing of plano

patented technology: A-WPT (Advanced Wheel Polishing Tool)

conventional wheel polishing = directional structures A-WPT =

16 A-WPT Advanced Wheel Polishing Technology Polishing of plano optics, spheres and aspheres using sub-aperture tools: OptoTech patented technology: A-WPT (Advanced Wheel Polishing Tool) Optimized kinematics by introducing an additional axis of rotation conventional wheel polishing = directional structures A-WPT = isotropic surface texture Improved surface quality combined with highest removal rates!

A-FJP Active Fluid Jet Polishing A-FJP Corrective

polishing slurry - eccentrically rotating movement

correction of low-spatial frequencies - excellent

felt on rubber pin R a = 1,39 nm (R q = 1,74 nm)

17 A-FJP Active Fluid Jet Polishing A-FJP Corrective Polishing - polishing pin pressed to surface by polishing slurry - eccentrically rotating movement along raster or spiral path - highly deterministic correction of low-spatial frequencies - excellent surface quality depending on tool-type Polishing felt on rubber pin R a = 1,39 nm (R q = 1,74 nm) Pitch on PU foil on rubber pin R a = 0,29 nm (R q = 0,38 nm)

excellent smoothing of MSF s - excellent surface

18 Sub-Aperture Pitch Polishing Pitch Polishing with Sub-Aperture Tools - small partly elastic form tool - excellent smoothing of MSF s - excellent surface quality Micro-roughness achieved R a = 0.33 nm (R RMS = 0.42 nm)

19 Machine Platform Technologies introduced in this paper do require a machine platform with maximum freedom regarding versatility and machine kinematics OptoTech MCP series (Machine Centre for TCT: MCP 250 CNC

MCP Machine Series with MultiTool Technology 6-Axis

SynchroSpeed Polishing Active-Fluid Jet Polishing

20 MCP Machine Series with MultiTool Technology 6-Axis Polishing Machines of the MCP Series (Multi-Centre-Polishing) MCP 251 CNC MCP 501 CNC MCP 1001 CNC MCP 1501 CNC Polishing Technologies: SynchroSpeed Polishing Active-Fluid Jet Polishing Membrane Polishing A-WPT Polishing Sub Aperture Pitch Polishing Standard Pitch Polishing

21 Conclusion Different combinations of geometries, previous processes, error characteristics require different approach on polishing and fine correction technologies Specialisation requires different machines for a single task Generalisation enables one machine for different tasks: MultiTool Concept

22 Acknowledgements Erhard Brück: SynchroSpeed Polishing Roland Mandler: Advanced SynchroSpeed Polishing Sebastian Stoebenau: Process Development MultiTool

23 Questions? Matthias Pfaff T: E: W:

24 Thank you For your attention! OptoTech

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