Research on edge-control methods in CNC polishing

Background: We have developed edge-control for the Precessions TM process suitable for fast fabrication of large mirror segments, and other applications sensitive to edge mis-figure. This has been applied to processing of European extremely large telescope (E-ELT) prototype mirror-segments, meeting the specification on maximum edge mis-figure. However we have observed residuals that have proved impossible to correct with this approach, being in part the legacy of asymmetries in the input edge-profiles. Methods: We have therefore compared different proposed methods experimentally and theoretically and report here on a new edge-rectification step, which operates locally on edges, does not disturb the completed bulk area. Results: A new toolpath has been developed and experiments have been carried out to demonstrate that local edge rectification can be carried out. Conclusions: With this method, the residue error on edges can be removed separately and has potential to reduce total process time.