A Model and Experimental Study on the Surface Quality of Quartz Glass ground by Trochoidal Trajectory with Cup wheel grinding

With regard to space telescopes, the processing of large optical mirrors has always been a highlight in the field of optical processing. These mirrors are typically made of hard and brittle materials such as quartz glass, microcrystalline glass, and silicon carbide. These materials have long been considered challenging to work with due to their processing efficiency and propensity for damage. This study proposes a trochoid model considering the actual motion trajectory of the cup-grinding wheel with discrete consolidated abrasive grains. Through the establishment of a process parameter–mathematical model to establish the multi-grain coupled motion trajectory, the uniformity of the trajectory is optimized to increase the material removal rate and reduce the surface damage caused by abrasive interference. The process parameters and model were verified using an optical curve-grinding machine. The results show that the process parameter optimization using this model can effectively reduce the surface roughness of quartz glass grinding. The surface and sub-surface damage caused by grinding stress are significantly reduced, and the edge fracture area of quartz glass is decreased. The large contact area at the end face of the cup-grinding wheel enables a larger grinding depth while ensuring that cracks do not extend to the sub-surface, improving the overall surface integrity of the mirror.