In the high-power laser system, the mid-spatial frequency error of the surface of the high-power laser component will affect the normal operation of the high-power laser system. In order to improve the mid-spatial frequency error of the high-power laser component after magnetorheological finishing, the causes and influencing factors of the ribbon fluctuation in magnetorheological finishing are studied, and the influence of different ribbon fluctuation on the mid-spatial frequency error of the surface is studied. Firstly, the influence of different ribbon fluctuations on the mid-spatial frequency error of the machined surface is simulated by a computer. Secondly, the magnetic field in the circumferential direction of the polishing wheel, the fluctuation amount and frequency of the magnetorheological polishing ribbon are measured, and then the causes of the fluctuation of the magnetorheological polishing ribbon are analyzed. Moreover, through the principle of a single variable, the influence of process parameters on the fluctuation of magnetorheological polishing ribbon is explored. Finally, the fused silica component is scanned uniformly under the process parameters of magnetorheological polishing ribbon fluctuation of 40 μm, 80 μm, 150 μm, and 200 μm. The experimental results show that the greater the ribbon fluctuation, the greater the surface mid-spatial frequency error of the component, and the ribbon fluctuation is approximately linear with the RMS of the PSD2 in the mid-spatial frequency band on the surface of the component. Therefore, the fluctuation of the ribbon can be controlled by controlling the magnetorheological processing parameters, and the mid-spatial frequency band error on the surface of the high-power laser component can be significantly reduced by optimizing process parameters after magnetorheological finishing.

Abrasive water jet polishing has significant advantages in the manufacturing of complex optical components (such as high-slope optical component cavities) that require high-precision manufacturing. This is due to its processing process, in which the polishing tool does not make direct contact with the surface of the workpiece, and instead maintains a considerable distance. However, the removal functions of most existing abrasive water-jet polishing technologies do not possess strict symmetry, which significantly impacts the ability to correct surface figure errors. Therefore, this study implements rotating abrasive water-jet polishing based on traditional abrasive water jet processing to optimize the removal function, which turns it into a Gaussian form; thus, obtaining a type of removal function more suitable for CCOS polishing. This paper derives an empirical formula between the distance s’ from the peak removal point of the removal function to the stagnation point and the nozzle tilt angle α, based on geometric relationships and experimental results, analyzes the relationship between material removal efficiency, nozzle tilt angle, and standoff distance. Finally, this paper verifies through experiments the validity of this empirical formula under different process parameters. Therefore, this study obtains the process conditions that allow rotating abrasive water-jet polishing technology to achieve a stable Gaussian form removal function, and the appropriate process parameters to be selected in conjunction with polishing efficiency; thereby, effectively improving the removal function’s corrective ability and manufacturing efficiency. It provides theoretical support for the processing capability and process parameter selection of abrasive water-jet polishing technology, solves the problem of limited shaping capability of existing abrasive water jet tools, and significantly improves the manufacturing capability of high-end optical components.

As a key component of a high-power laser device, fused silica optics needs to bear great laser energy, and laser damage is easily generated on the optical surface. In order to improve the service life and availability of optics, it is necessary to repair the damaged optics. In this work, the repair technique of damaged, fused silica optics was studied. The neural network method was mainly used to establish the correlation between the number of small-scale damage points and the repair depth. The prediction accuracy of the model is better than 90%. Based on the neural network model, the removal depth parameters were optimized with the suppression coefficient of the damage points. The processing effect of the optimized parameters was verified by magnetorheological polishing experiments. In this paper, a repair technique based on a neural network was proposed, which avoids the low efficiency caused by processing iterations in the repair process, and can accurately what was expected. The method proposed in this work has an important reference value in the repair process of fused silica optics.

Abrasive water jet polishing (AWJP), as an ultra-precision machining technology, has unique machining advantages. However, the machining application of nozzles in vertical and inclined states is greatly limited because rotational symmetric material removal characteristics and the largest amount of central material removal cannot be obtained. At the same time, considering the many controllable and uncontrollable factors in AWJP, it is difficult to accurately model the removal characteristics obtained by machining. Based on the idea of the Preston equation and the calculation of fluid dynamics, this study first analyzed the material removal characteristics of a single abrasive particle and used FLUENT fluid simulation software to obtain the pressure and velocity distributions at different positions in the processes of nozzle rotation and tilt polishing. By analyzing the influence of the pressure and velocity distributions on material removal and the surface shear stress of the workpiece, a theoretical model of the material removal characteristics of abrasive water jet polishing under rotating oblique incidence was established. Finally, the effectiveness of the theoretical removal model was verified by comparing and analyzing experimental and theoretical results.

Laser additive manufacturing (AM) technology has become an important method for the manufacturing of high-performance aluminum alloy parts. However, the thermal effect of the molten pool and the defect formation mechanism are still the key issues restricting forming quality. To address this issue, this paper systematically investigates the effects of key parameters such as laser power and pulse frequency on the thermal conductivity, kinetic behavior, and defect control of the molten pool through multi-physics coupled numerical simulation to provide theoretical support for improving the quality of components. It is found that the laser power and pulse frequency play a key role in the molten pool morphology and defect generation, with too low a power leading to non-fusion and too high a power triggering overheating and cracking, and too low a frequency leading to unstable morphology and too high a frequency triggering grain coarsening and thermal stress cracking. The optimized process parameters (power 700–800 W, frequency 72–100 KHz) effectively improved the melt pool morphology and reduced the defects. This study reveals the intrinsic mechanism of melt pool dynamics and defect formation, which provides important instructions for optimizing the aluminum alloy additive manufacturing process.