Abstract A large demand for micro cylinder array lenses on the scale of 0.1∼10 mm exists for laser beam shaping in optical communication and measurement devices. Envelope grinding is an attractive method for the efficient fabrication of optical lenses. However, precision truing of micro-diamond grinding wheels is very arduous. In this paper, a novel method of envelope grinding using a near arc-profile wheel (EGNAW) without on-machine precision truing is proposed for micro-cylinder array lenses fabrication. The mathematical models of near arc-profile wheels and the wheel path in the workpiece profile plane are established. Comparative experiments of conventional envelope grinding and the EGNAW method are conducted on BK7 glass elliptical curved micro-cylinder array lenses. The three step strategies for the EGNAW method, that is, the iso-parametric, iso-distance and iso-residual strategies, are investigated for their effects on the grinding results. The normal error (in PV) of the micro-lens ground using the conventional envelope grinding is 33.48 μm. The normal error in the EGNAW method is minimized to 2.05 μm. For the EGNAW method, the grinding accuracy and surface roughness of a lens ground using the iso-distance or iso-residual strategy are superior to those of the iso-parametric strategy at the same efficiency. The EGNAW method can be applied to cylindrical surfaces as well as rotationally symmetric and non-rotationally symmetric freeform surfaces.

中文翻译：

---

使用近弧形砂轮对微柱面阵列透镜进行包络磨削，无需在机上进行精密修整

摘要 光通信和测量设备中的激光束整形对0.1～10 mm尺度的微柱面阵列透镜有很大的需求。包络研磨是一种有效制造光学透镜的有吸引力的方法。然而，微金刚石砂轮的精密修整非常艰巨。在本文中，提出了一种使用近弧轮廓砂轮 (EGNAW) 进行包络磨削的新方法，该方法无需在机上进行精确修整，用于微柱面阵列透镜制造。建立了近圆弧轮廓轮和工件轮廓平面内的轮径数学模型。在BK7玻璃椭圆曲面微柱面阵列透镜上进行了常规包络磨削和EGNAW方法的对比实验。EGNAW 方法的三步策略，即等参数，研究了等距和等残差策略对研磨结果的影响。使用传统包络研磨的微透镜研磨的正常误差（以 PV 为单位）为 33.48 μm。EGNAW 方法中的正常误差最小化到 2.05 μm。对于EGNAW方法，在相同效率下，使用等距或等残差策略研磨的镜片的研磨精度和表面粗糙度优于等参数策略的研磨精度和表面粗糙度。EGNAW 方法可以应用于圆柱表面以及旋转对称和非旋转对称的自由曲面。EGNAW 方法中的正常误差最小化到 2.05 μm。对于EGNAW方法，在相同效率下，使用等距或等余量策略研磨的镜片的研磨精度和表面粗糙度优于等参数策略的研磨精度和表面粗糙度。EGNAW 方法可以应用于圆柱表面以及旋转对称和非旋转对称的自由曲面。EGNAW 方法中的正常误差最小化到 2.05 μm。对于EGNAW方法，在相同效率下，使用等距或等残差策略研磨的镜片的研磨精度和表面粗糙度优于等参数策略的研磨精度和表面粗糙度。EGNAW 方法可以应用于圆柱表面以及旋转对称和非旋转对称的自由曲面。