RESEARCH ARTICLE

Full-band error control and crack-free surface fabrication techniques for ultra-precision fly cutting of large-aperture KDP crystals

  • F. H. ZHANG , 1 ,
  • S. F. WANG 1,2 ,
  • C. H. AN 2 ,
  • J. WANG 2 ,
  • Q. XU 2
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  • 1. Department of Mechanical Engineering, Harbin Institute of Technology, Harbin 150001, China
  • 2. Chengdu Fine Optical Engineering Research Center, Chengdu 610041, China

Received date: 10 Sep 2016

Accepted date: 04 Mar 2017

Published date: 19 Jun 2017

Copyright

2017 Higher Education Press and Springer-Verlag Berlin Heidelberg

Abstract

Large-aperture potassium dihydrogen phosphate (KDP) crystals are widely used in the laser path of inertial confinement fusion (ICF) systems. The most common method of manufacturing half-meter KDP crystals is ultra-precision fly cutting. When processing KDP crystals by ultra-precision fly cutting, the dynamic characteristics of the fly cutting machine and fluctuations in the fly cutting environment are translated into surface errors at different spatial frequency bands. These machining errors should be suppressed effectively to guarantee that KDP crystals meet the full-band machining accuracy specified in the evaluation index. In this study, the anisotropic machinability of KDP crystals and the causes of typical surface errors in ultra-precision fly cutting of the material are investigated. The structures of the fly cutting machine and existing processing parameters are optimized to improve the machined surface quality. The findings are theoretically and practically important in the development of high-energy laser systems in China.

Cite this article

F. H. ZHANG , S. F. WANG , C. H. AN , J. WANG , Q. XU . Full-band error control and crack-free surface fabrication techniques for ultra-precision fly cutting of large-aperture KDP crystals[J]. Frontiers of Mechanical Engineering, 2017 , 12(2) : 193 -202 . DOI: 10.1007/s11465-017-0448-8

Acknowledgments

The authors would like to express their sincere gratitude to the National Natural Science Foundation of China (Grant Nos. 51535003 and 51275115) and the Ultra-Precision Technology Key Laboratory of China Academy of Engineering Physics (Grant No. zz14002) for providing financial support.
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