A conformal processing method

Abstract

The present invention proposes a conformal processing method, which adds a filling medium between a blank optical element and a mounting frame, and processes the blank optical element, the mounting frame and the filling medium together to ensure the shape and position accuracy of the optical element while eliminating the gap of the conformal surface to make the conformal surface flat and smooth, and processes a stress relief structure on a limiting protrusion that limits the relative position of the optical element, thereby reducing the accuracy requirements for the optical element and the mounting frame during the processing process, and at the same time, by using and processing parts whose material properties and spatial shape and size can match each other, the processed object can have thermal stress relief properties and the ability to adapt to pressure changes and resist impact vibrations; the conformal processing method overcomes the problems of existing processing methods such as gaps on the conformal surface, difficulty in directly obtaining high shape and position accuracy for optical elements, unstable performance of the processed device, and high requirements on the accuracy of parts and components and great processing difficulty.

Description

Technical Field

[0001] The invention belongs to the technical field of conformal processing, and in particular relates to a conformal processing method. Background Art

[0002] Some optical instruments used in high-speed fluids often need to meet certain aerodynamic shapes. For example, a conformal hood for high-speed flight requires a surface of a specific shape in order to reduce drag, and the surface must be flat and smooth. At the same time, in order to achieve optical functions such as observation, optical elements such as lenses must be installed, and the optical elements must not destroy the aerodynamic shape of the hood. Therefore, how to obtain a smooth and conformal surface by processing optical elements and mounting frames of different materials has become a difficult problem. Because the optical elements used in conformal devices not only need to meet high shape accuracy, but also need to maintain high position accuracy with other optical elements. For lens-type optical elements, high position accuracy must also be achieved between their own multiple optical surfaces. Conventional processing methods process optical elements and mounting frames separately, and then manually assemble and adjust the device to meet the accuracy requirements. This is very time-consuming and labor-intensive, and it is difficult to meet the needs of mass production of conformal devices. At the same time, in order to achieve a smooth and flat conformal surface, the existing processing method is to process the positioning and mounting surfaces of the optical element and the mounting frame to very high precision respectively, so as to reduce the gap generated by the mounting joint of the two as much as possible, thereby achieving a smooth and flat effect. However, since the optical elements used in the conformal device are mostly embedded in the mounting frame, the mounting surface of the mounting frame is closed, and the mounting surface of the mounting frame may even be a curved surface, so it is difficult to process a high-precision positioning and mounting surface; at the same time, since the optical elements of the conformal device are mostly non-circular and thin, and the hard and brittle characteristics of the material, it is also difficult to process a high-precision mounting and positioning surface for them; even if high-precision mounting and positioning surfaces can be processed on the mounting frame and the optical element, a certain gap must be reserved for installation needs, so it is also difficult to completely achieve the effect of a smooth and flat conformal surface. Even if an adhesive is used in the process of mounting the optical element on the mounting frame, its purpose is to fix the optical element. At the same time, due to the thin thickness of the adhesive and the inability to cover the gap between the optical element and the mounting frame and the junction of the conformal surface, the use of the adhesive cannot solve the problem that the conventional processing method cannot make the conformal surface flat and smooth. At the same time, the conformal device used for high-speed fluids will experience severe environments such as rapid changes in pressure and temperature and impact vibration. For example, the pressure on the outer surface of the conformal head cover flying at high speed will decrease, and the temperature of the outer surface will increase due to friction. It will also be subjected to impact and vibration due to high-speed flight. The conformal device processed by the existing processing method can only meet the accuracy requirements in a relatively stable environment due to the lack of temperature adaptability and buffer structure. When the actual working conditions are relatively bad, it is difficult to ensure the stability of the device's shape and position accuracy. Therefore, there is currently a lack of a conformal processing method that can make the conformal surface truly flat and smooth, and can also make the conformal device meet the accuracy requirements without adjustment, and can also ensure that the processed device can adapt to harsh working environments and has low processing requirements. Summary of the invention

[0003] In order to specifically overcome the problems existing in the existing conformal processing methods, such as high requirements on parts precision and great processing difficulty, inability to completely eliminate the gap between the joint surface of the optical element and the mounting frame, inability to directly enable the device to obtain the required shape and position precision and need for adjustment, and inability to enable the processed device to adapt to harsh working environments, the present invention proposes a conformal processing method that can reduce the requirements on parts processing precision, can make the joint surface between the optical element and the mounting frame smooth and flat, can enable the optical element and the mounting frame to directly obtain the required shape and position precision, and can enable the processed conformal device to have the property of eliminating thermal stress and adapt to pressure changes and resist impact vibration.

[0004] The present invention is achieved by adopting the following technical solutions:

[0005] A conformal processing method, characterized in that it comprises the following steps:

[0006] Step 1: Prepare the required parts and process them into a rough shape, leaving enough processing allowance for subsequent processes;

[0007] Step 2: Processing a blank of the optical element, processing the positioning surface of the blank optical element to the designed size, and leaving enough processing allowance for subsequent processing of the optical surface of the blank optical element;

[0008] Step 3: Processing a mounting surface for mounting the rough optical element on the mounting frame, wherein the mounting space formed by the mounting surface is larger than the rough optical element to be mounted according to design parameters, so that a predetermined gap is formed between the rough optical element and the mounting frame after the mounting, thereby injecting a filling medium into the predetermined gap; and processing or installing a limiting protrusion on the mounting surface, wherein the limiting protrusion does not protrude from the mounting frame on the side of the conformal surface to be processed, and has a corresponding distance from the conformal surface, so that the filling medium can completely cover the mounting surface of the mounting frame and the corresponding positioning surface of the rough optical element, and the corresponding distance refers to the distance at which the limiting protrusion does not protrude from the conformal surface after the conformal surface is processed and the filling medium at this location has sufficient thickness to ensure its own strength. Multiple limiting protrusions can be arranged vertically and horizontally to better position and support the optical element and strengthen the filling medium, and at the same time, the rigidity and volume and other properties of a single limiting protrusion can also be better adjusted;

[0009] Step 4: Install the processed flow guide on the corresponding side of the installation frame, where the corresponding side refers to the side that subsequently intercepts and guides the injected filling medium and prevents it from flowing out. At the same time, the flow guide can also serve as an auxiliary positioning piece for the subsequent installation of the blank optical element;

[0010] Step 5: Install the processed rough optical element in the installation space formed by the installation surface processed on the installation frame, and determine the position of the rough optical element with the assistance of the limiting protrusion and the guide member. After installation, a predetermined gap is left between the installation surface of the installation frame and the positioning surface corresponding to the rough optical element, and the predetermined gap is used for subsequent injection of the filling medium.

[0011] Step 6: Inject a filling medium with a certain fluidity into the cavity formed by the mounting frame, the rough optical element and the guide piece. The fluidity enables the filling medium to adapt to any shape and various processing errors of the mounting surface of the mounting frame and the positioning surface corresponding to the rough optical element. After solidification and stabilization, the filling medium can fill the predetermined gap between the mounting surface of the mounting frame and the positioning surface corresponding to the rough optical element. The filling medium has a certain strength to fix the optical element and is convenient for subsequent processing. After the corresponding processing steps, a smooth, flat, firm and reliable surface can be formed.

[0012] Step 7: After the filling medium to be injected solidifies and stabilizes, the guide piece is removed;

[0013] Step 8: Clamp the mounting frame after removing the guide piece, the rough optical element and the filling medium together on a processing machine tool;

[0014] Step nine, using a corresponding processing machine tool to process the shape-conserving device to be processed, which is composed of the mounting frame, the filling medium and the rough optical element;

[0015] Step 10: Perform precision testing on the processed conformal device, especially the optical element. If the test fails, repeat the processing and testing steps until the test passes.

[0016] The flow guide can be processed together with the mounting surface of the mounting frame as a part of the mounting frame in step three, and the flow guide is removed together with the mounting frame, the filling medium and the rough optical element in step nine;

[0017] When multiple surfaces of the mounting frame and the blank optical element need to be processed conformally, the remaining required flow guides are timely installed on the corresponding parts of the mounting frame and the blank optical element before the filling medium is injected, so that after the subsequent injection of the filling medium, the corresponding surfaces of the blank optical element and the mounting frame can be completely filled and covered;

[0018] In the case where the flow guide is mounted on the mounting frame, the flow guide can be removed after the mounting frame, the blank optical element and the filling medium are clamped on the processing machine. In the case where the flow guide does not affect subsequent processing, it can also be removed together with the subsequent processing of the mounting frame, the filling medium and the blank optical element.

[0019] If the measurement conditions are not available or the processing quality is controllable and reliable, the measurement step can be cancelled, and the processing results can be checked by the actual performance of the device;

[0020] When the blank optical element can be positioned by the limiting protrusion, for example, the optical element is bonded to the limiting protrusion, the guide member can be installed on the mounting frame in due time after the blank optical element is mounted on the limiting protrusion.

[0021] Furthermore, a stress relief structure is processed on the limiting protrusion, which is multi-directional and has at least one stress relief direction that is the same as the limiting direction of the limiting protrusion on the optical element. In this way, when the blank optical element is installed, a certain processing error can be allowed for multiple parts such as the blank optical element, the limiting protrusion and the mounting frame, while reducing the stress impact caused by the harsh environment.

[0022] Furthermore, in step three, the limiting protrusion can be processed to a general precision. Due to the existence of the stress relief structure, even if the limiting protrusion is slightly larger, a certain pressure can be generated on the blank optical element. If the limiting protrusion is slightly smaller, the blank optical element also has sufficient processing allowance, so that the final surface shape falls within the envelope of the allowance.

[0023] Furthermore, the optical element, the mounting frame and the limiting protrusions are processed to the designed dimensions so that the spatial dimensions of the optical element, the mounting frame and the filling medium cooperate with the material properties to produce thermal stress elimination properties, thereby greatly reducing the impact of temperature changes on the performance of the conformal device.

[0024] Furthermore, the filling medium injected in step six is ​​composed of one or more materials, and the filling medium can be injected in batches for multiple times, so that the filling medium forms a layered structure in the horizontal or vertical direction to exert its advantages in mechanics and stability. The filling medium has affinity for the mounting frame and optical elements in contact with itself, wherein a variety of materials can increase the freedom of selection of filling medium materials, and the affinity can make the filling medium more closely combined with the optical elements and the mounting frame, thereby making the processed conformal surface, especially the junction of different parts, smoother.

[0025] Furthermore, due to the existence of the limiting protrusion stress relief structure, sufficient processing allowance for the optical surface to be processed of the blank optical element, and the filling effect of the fluid filling medium and other factors that allow a certain error to exist, it is sufficient to process the positioning surface of the blank optical element to a general accuracy in step 2, because even if there is a certain error in the positioning surface of the blank optical element, the shape and position accuracy of its optical surface after processing can be guaranteed.

[0026] Furthermore, due to the existence of the limiting protrusion stress relief structure, the sufficient processing allowance left for the optical surface of the blank optical element to be processed, and the filling effect of the fluid filling medium and other factors that allow a certain error to exist, when processing the mounting surface of the mounting frame for mounting the blank optical element in step three, it is sufficient to process it to a general accuracy.

[0027] Furthermore, the groove formed by the guide itself or by combination can completely cover the gap formed by the corresponding mounting surfaces and positioning surfaces of the mounting frame and the optical element, and span the mounting frame and the optical element, so that the injected filler can extend to cover a portion of the mounting frame and the optical element, thereby ensuring that the filling medium completely covers the gap between the optical element and the mounting frame and the junction of the conformal surface.

[0028] Furthermore, in the case where the guide piece needs to be removed from the mounting frame, the material of the guide piece itself is incompatible with the material of the filling medium, or a coating that is incompatible with the material of the filling medium is applied to the surface of the guide piece before the filling medium is injected, or a film that is incompatible with the material of the filling medium is covered, so that the guide piece can be removed after the filling medium solidifies and stabilizes without damaging the filling medium.

[0029] Furthermore, a mesh reinforcement structure is added to the filling medium at an appropriate time. The mesh reinforcement structure has a corresponding distance from the conformal surface to be processed. The mesh reinforcement structure can make the filling medium more solid while also adjusting the overall stiffness of the filling medium and increasing the overall toughness of the filling medium. Keeping a corresponding distance from the conformal surface to be processed is to prevent the mesh reinforcement structure from exposing the conformal surface after processing and destroying the flatness and smoothness of the conformal surface.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] A conformal processing method is disclosed, wherein a filling medium is added between a blank optical element and a mounting frame, and the blank optical element, the mounting frame and the filling medium are processed together to ensure the initial shape and position accuracy of the optical element while eliminating the gap of the conformal surface so that the conformal surface is flat and smooth, so that the processed optical element and the mounting frame are truly integrated; and a stress relief structure is processed on a limiting protrusion that limits the relative position of the optical element, and sufficient processing allowance is reserved on the optical surface to be processed of the blank optical element, and factors such as a fluid filling medium that can allow a certain error to exist are injected, so that all the mounting and positioning surfaces of the optical element, the mounting frame, the limiting protrusion and other components that cooperate with each other only need to achieve general accuracy, thereby reducing the accuracy requirements for the optical element, the mounting frame, the limiting protrusion and other components during the processing; and at the same time, by using and processing components whose material properties and spatial shape and size can cooperate with each other, the processed object has the property of thermal stress relief and the ability to resist pressure changes and impact vibrations, so that the processed conformal device can improve the stability of its shape and position accuracy, thereby improving the reliability of the processing process and the adaptability to harsh working environments. The conformal processing method overcomes the problems existing in the prior processing methods, such as gaps in the conformal surface, difficulty in directly obtaining high shape and position accuracy for optical elements, unstable performance of the processed device, and high processing difficulty due to high precision requirements for parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of the structure of the pipeline and the optical side window in the present invention;

[0033] Figure 2 It is a schematic diagram of the structure of the limiting protrusion in the present invention;

[0034] Figure 3 It is a schematic diagram of the structure after the inner flow guide member of the present invention is installed;

[0035] Figure 4 This is a schematic diagram of the structure of the blank optical side window after installation in the present invention;

[0036] Figure 5 It is a schematic diagram of the structure after the outer flow guide member is installed in the present invention;

[0037] Figure 6 It is a schematic structural diagram of the shape-preserving device to be processed before the filling medium is injected in the present invention;

[0038] Figure 7 It is a schematic structural diagram of the shape-preserving device to be processed after the filling medium is injected in the present invention;

[0039] Figure 8 It is a schematic diagram of the cross-sectional structure of the shape-conserving device to be processed after the filling medium is injected in the present invention;

[0040] Fig. 9 It is a schematic structural diagram of the shape-preserving device to be processed after the inner and outer flow guide members are removed in the present invention;

[0041] Fig.10 It is a schematic diagram of the cross-sectional structure of the shape-preserving device to be processed after the inner and outer flow guide members are removed in the present invention;

[0042] Fig.11 It is a schematic diagram of clamping the shape-preserving device in the present invention;

[0043] Fig.12 It is a schematic diagram of the structure of the shape-preserving device after processing in the present invention;

[0044] Fig.13 It is a schematic diagram of the stress relief structure of the limiting protrusion in the present invention;

[0045] Fig.14 This is a schematic diagram of the dual optical side window structure of the present invention;

[0046] Fig.15 It is a schematic diagram of the limiting protrusion without stress relief structure in the present invention.

[0047] Legend: 1: Pipe, 2: Optical side window, 3: Limiting protrusion, 4: Inner flow guide, 5: Outer flow guide, 6: Filling medium, 7: Adapter plate, 8: Spindle, 9: Pipe mounting surface, 10: Side window positioning surface.

[0048] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0049] The following will be combined with the drawings of the present invention to clearly and completely describe the technical solution of the present invention. Obviously, the description including the drawings is only a part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0050] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0051] In addition, in the present invention, descriptions such as "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" or "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0052] In the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, an electrical connection, a physical connection, or a wireless communication connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0053] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in the field can implement it. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0054] As attached Figure 1-15 As shown, in order to clearly demonstrate the principle and working process of the present invention, this embodiment provides a more typical implementation plan through the processing process of a pipeline-type conformal device, but the following case is only a typical embodiment of the present invention and cannot represent all the solutions of the present invention.

[0055] The pipeline-type conformal device as shown in the figure is used to observe the flow state of the high-speed fluid inside the pipe body. In order not to introduce external errors, it is necessary not to destroy the original shape of the pipe while realizing the observation function. Therefore, the inner surface of the optical side window 2 must be kept in the same shape as the inner surface of the pipe 1, that is, the mounting frame, to achieve conformal. Local convexity and gaps are not allowed to exist on the conformal surface, otherwise it will also affect the high-speed fluid. Therefore, the processing method proposed in the present invention can be used to achieve conformal processing of the pipeline-type conformal device.

[0056] The optical side window 2 in the present pipeline conformal device can be regarded as a lens, which is made of optical material that can be turned. At the same time, as an optical element, it is non-circular in shape and thin in thickness, so it is difficult to process a high-precision positioning surface. As the pipeline 1 is used as a mounting frame, the optical side window 2 needs to be embedded in the pipeline 1, so the pipeline mounting surface 9 on which the optical side window 2 is mounted constitutes a closed rectangle, which is also difficult to be processed with high precision. In addition, in order to facilitate installation, the rectangle formed by the pipeline mounting surface 9 should be slightly larger than the overall size of the optical side window 2. Even if an adhesive is used in the conventional processing method, it is mainly to fix the optical side window 2 on the pipeline 1, and it does not have the function of completely filling the gap. The above factors lead to the inevitable appearance of a gap at the junction of the side window positioning surface 10 and the pipeline mounting surface 9 when using the traditional processing method.

[0057] At the same time, the thermal expansion coefficient of optical materials is often quite different from that of metal materials. This means that even if the side window positioning surface 10 and the pipe mounting surface 9 can be processed with high precision and the gap can be eliminated as much as possible through a close fit between the two, when the working environment has changes in temperature, the pipe 1 will squeeze or peel off the optical side window 2 due to the different thermal deformation amounts with the optical side window 2, which may cause deformation or even damage to the optical side window 2 or debonding, pulling, etc.; and when the pressure changes due to the high-speed flow of the fluid, if the optical side window 2 and the pipe 1 are too tightly fitted in order to eliminate the gap, the performance of the conformal device will also be affected by the deformation; at the same time, because the conformal device used for high-speed fluid has a high environmental vibration frequency, it is easy for the conformal device to resonate, and the impact caused by the resonance will also affect the performance of the unbuffered conformal device processed by the traditional processing method.

[0058] like Fig.14 As shown, when multiple optical side windows 2 need to be installed on the pipe 1 to cooperate with each other to realize the observation function, high position accuracy must be maintained between the multiple optical side windows 2. At the same time, for the lens-type optical side window 2, high position accuracy must also be achieved between its own two optical surfaces. The conventional processing method is to process the optical side window 2 and the pipe 1 separately, and then manually assemble and adjust the device to meet the accuracy requirements, which is very time-consuming and labor-intensive, and it is difficult to meet the needs of mass production.

[0059] Therefore, it is difficult for traditional processing methods to overcome the above-mentioned contradictory problems.

[0060] The processing of the pipeline conformal device can be carried out as follows:

[0061] Step 1: Prepare the required parts and process them into a rough shape, leaving enough processing allowance for subsequent processes;

[0062] Step 2: Processing the blank of the optical side window 2, processing the side window positioning surface 10 of the blank optical side window 2 to the required size, and leaving enough processing allowance for subsequent processing of the two optical surfaces of the blank optical side window 2. The processing allowance can be appropriately left more to reserve more error space for other parts;

[0063] Step three, a pipe installation surface 9 for installing the rough optical side window 2 is processed on the pipe 1, and the rectangular installation space formed by the pipe installation surface 9 is larger than the overall external dimensions of the rough optical side window 2 to be installed according to the design parameters, so that a predetermined gap is formed between the rough optical side window 2 and the pipe 1 after the installation, thereby injecting a filling medium 6 into the predetermined gap; and a limiting protrusion 3 is processed or installed on the pipe installation surface 9, and the limiting protrusion 3 does not protrude from the inner surface of the pipe 1 on the conformal surface side of the inner wall of the pipe to be processed, and has a corresponding distance from the inner surface of the pipe 1, so that the filling medium 6 can completely cover the pipe installation surface 9 and the side window positioning surface 10 and ensure a certain strength; the corresponding distance refers to the distance that the limiting protrusion 3 does not protrude from the conformal surface after the conformal surface is processed and the filling medium there has sufficient thickness to ensure its own strength; the limiting protrusion 3 can be arranged vertically and horizontally on the pipe installation surface 9 according to the actual conditions such as the shape and size of the optical side window 2, such as Fig.14 As shown, the optical side window 2 can be better positioned and supported, and the rigidity and volume of a single limiting protrusion 3 can also be better adjusted;

[0064] Step 4: Install the processed inner flow guide 4 on the corresponding position of the inner pipe wall side of the pipeline 1 for installing the blank optical side window 2, such as Figure 3 As shown, the inner guide member 4 can be used as an auxiliary positioning member for the subsequent installation of the blank optical side window 2;

[0065] Step 5: Install the processed rough optical side window 2 in the rectangular installation space formed by the pipeline installation surface 9 processed by the pipeline 1, and determine the position of the rough optical side window 2 with the assistance of the limiting protrusion 3 and the inner guide 4, as shown in FIG. Figure 4 As shown, an adhesive can be applied at the contact point between the limiting protrusion 3 and the blank optical side window 2 to better fix the blank optical side window 2. After installation, a predetermined gap is left between the pipe installation surface 9 of the pipe 1 and the side window positioning surface 10 corresponding to the blank optical side window 2, and the predetermined gap is used for subsequent injection of the filling medium 6;

[0066] Step 6: Inject a filling medium 6 with a certain fluidity into the cavity formed by the pipeline 1, the rough optical side window 2 and the inner guide member 4. The fluidity enables the filling medium 6 to adapt to any shape of the pipeline installation surface 9 and the corresponding side window positioning surface 10 and various processing errors including surface microscopic defects and dimensional errors. After solidification, the filling medium 6 can fill the predetermined gap between the pipeline installation surface 9 and the corresponding side window positioning surface 10. The filling medium 6 has a certain strength after solidification, which can reliably fix the optical side window 2 and facilitate subsequent processing. After the corresponding processing steps, a smooth, flat, firm and reliable surface can be formed. A feasible material selection scheme for the filling medium 6 is the improved epoxy resin.

[0067] Step 7: After the filling medium 6 to be injected solidifies and stabilizes, the inner flow guide 4 is removed;

[0068] Step 8: After removing the inner guide member 4, the pipe 1 together with the rough optical side window 2 and the filling medium 6 are clamped on a processing machine. Fig.11 As shown, the pipeline conformal device to be processed can be clamped on the spindle 8 through the adapter plate 7, and can be processed by a single-point diamond turning machine. Since the pipeline conformal device has a rotationally symmetrical shape, and the pipeline 1, the optical side window 2 and the filling medium 6 can all be turned, in order to obtain a high-precision conformal surface, the above-mentioned single-point diamond turning, an ultra-precision processing method, can be selected to process the pipeline conformal device;

[0069] Step nine, using a single-point diamond turning machine to process the shape-conserving device to be processed, which is composed of the pipe 1, the filling medium 6 and the rough optical side window 2;

[0070] Step 10: Perform precision testing on the processed conformal device, especially the optical side window 2. If the test fails, repeat the above processing and testing steps until the test passes.

[0071] In the above processing, the inner flow guide 4 can be used as a part of the pipeline 1, that is, the two are an integrated structure, and in step three, it is processed together with the pipeline installation surface 9 of the pipeline 1, and then the inner flow guide 4 is removed together with the processing of the pipeline 1, the filling medium 6 and the blank optical side window 2 in step nine;

[0072] In some special usage scenarios, when both sides of the pipe 1 and the blank optical side window 2 need to be processed conformally, after the blank optical side window 2 is installed on the pipe 1, the outer guide 5 is installed on the other side of the pipe 1 and the blank optical side window 2, such as Figure 4 and Figure 5 As shown, after the filling medium 6 is subsequently injected, the corresponding positions of the optical side window 2 and the two sides of the pipeline 1 can be completely filled and covered;

[0073] In the case where the flow guide is installed on the pipe 1, the flow guide can be removed after the pipe 1, the blank optical side window 2 and the filling medium 6 are clamped on the single-point diamond turning machine. In the case where the flow guide does not affect the subsequent processing, it may not be removed. For example, the flow guide is a plastic part with very low strength, and is removed together with the processing of the pipe 1, the filling medium 6 and the blank optical side window 2.

[0074] If the measurement conditions are not available or the processing quality is controllable and reliable, the measurement step can be cancelled, and the processing result can be tested by the actual performance effect of the pipeline conformal device;

[0075] In the case where the position of the blank optical side window 2 can be determined by the limiting protrusion 3, for example Figure 2 By directly bonding the optical side window 2 to the limiting protrusion 3, the position of the blank optical side window 2 can be determined without relying on the assistance of the limiting protrusion 3. The guide piece can be installed on the pipe 1 in a timely manner after the blank optical side window 2 is installed on the limiting protrusion 3 and before the filling medium 6 is injected.

[0076] like Fig.13 As shown, a stress relief structure is processed on the limiting protrusion 3. Due to the stress relief structure, part of the material is removed so that the limiting protrusion 3 weakens the local rigidity as expected. Therefore, the stress relief structure in the figure has multi-directionality. In addition, the main stress relief direction of the limiting protrusion 3 is the same as its limiting direction for the optical side window 2, that is, perpendicular to the pipeline installation surface 9 and the side window positioning surface 10. Because it has weak rigidity in this direction, it can be compressed or stretched without generating excessive stress on the optical side window 2. In this way, when the blank optical side window 2 is installed, a certain processing error can be allowed for the blank optical side window 2, the limiting protrusion 3, the pipeline 1 and other parts, and a certain degree of deformation and displacement can be allowed for each component in multiple directions, thereby better reducing the negative impact of stress deformation caused by harsh working conditions.

[0077] The overall rigidity of the limiting protrusion 3, or the amount of material removed from the limiting protrusion 3 during processing, mainly depends on factors such as the strength of the support required for the optical side window 2. For example, when the optical element is subjected to strong external forces during operation, such as Fig.15 When the optical side window 2 shown in the figure is subjected to a large pulling force in the radial direction of the pipeline 1, that is, in the vertical direction shown in the figure, due to changes in external pressure, the overall rigidity of the limiting protrusion 3 should be improved, and even no stress relief treatment should be performed, or the limiting protrusion 3 should not be subjected to stress relief processing in the radial direction where the optical side window 2 is subjected to tension, and only the remaining limiting protrusions 3 should be subjected to stress relief processing in the remaining directions. At this time, the limiting protrusion 3 that is not subjected to stress relief processing in the radial direction should only contact the optical side window 2 in the radial direction, and should not affect the functioning of the stress relief structure of the remaining limiting protrusions 3. A specific structural form is as follows: Fig.15 shown.

[0078] In contrast, due to the existence of the stress relief structure, even if the limiting protrusion 3 is slightly larger, it can still generate a certain pressure on the blank optical side window 2. If the limiting protrusion 3 is slightly smaller and the limiting effect on the blank optical side window 2 is insufficient, the blank optical side window 2 also reserves sufficient processing allowance to overcome the dimensional error of the limiting protrusion 3 and allow the final surface shape to fall within the envelope of the allowance, and the fluid filling medium 6 can also fix the optical side window 2. Therefore, when processing the limiting protrusion 3 in step three, it is sufficient to process it to a general precision.

[0079] In order to reduce the impact of temperature changes on the performance of the conformal device during use, the optical side window 2, the pipeline 1 and the filling medium 6 are processed to predetermined dimensions so that the spatial dimensions of the three and their material properties can cooperate with each other to produce thermal stress elimination properties, thereby reducing the impact of temperature changes on the performance of the conformal device. Specifically, with reference to the legend, taking the thermal stress elimination process along the axial direction of the pipe 1 as an example, in this direction, due to the different thermal expansion coefficients of the optical side window 2 and the pipe 1 materials, generally speaking, the thermal expansion coefficient of optical glass is lower than that of the metal frame. Therefore, if the optical side window 2 is tightly combined with the pipe mounting surface 9, then when the temperature drops, the contraction of the pipe 1 will be greater than the contraction of the optical side window 2, and the pipe 1 will squeeze the optical side window 2, causing deformation or even damage to the optical side window 2; and if the temperature rises, the pipe mounting surface 9 will not adequately position the optical side window 2; at the same time, if the traditional adhesive fixing method is used, due to the tight combination of the optical side window 2 and the pipe mounting surface 9, the adhesive is too thin, etc., which can easily cause debonding and other problems. Even if mechanical fixing methods such as bolts are used, the optical side window 2 will be pulled.

[0080] By this processing method, the axial length of the optical side window 2, the axial spacing of the pipe mounting surface 9 and the axial thickness of the filling medium 6 are reasonably controlled, and the thermal expansion coefficients of the three materials are matched, so that the sum of the axial thermal deformation of the optical side window 2 and the axial thermal deformation of the filling medium 6 under temperature change conditions is equal to the axial thermal deformation between the pipe mounting surfaces 9, and the above-mentioned thermal stress elimination property can be achieved, so that there will be no problems such as squeezing or pulling and debonding of the optical side window 2. At the same time, processing a stress relief structure on the limiting protrusion 3 can also make the device better adapt to the deformation stress caused by temperature changes and pressure changes. For the above-mentioned spatial dimensions, conventional processing methods are sufficient to meet the precision requirements for the effectiveness of the thermal stress elimination property for components such as optical elements and mounting frames. Therefore, the realization of the thermal stress elimination property does not require the deliberate improvement of the processing accuracy of the components. At the same time, the optical element itself can allow the existence of a certain stress, and the soft connection constructed by the filling medium 6 and the limiting protrusion 3 can also absorb part of the stress, which further reduces the processing accuracy requirements for the components to achieve the thermal stress elimination function.

[0081] The filling medium 6 can be composed of one or more materials, and the materials can be mixed and injected at one time according to the material properties and functional requirements, or the filling medium 6 can be injected in batches for multiple times, so that the filling medium 6 forms a layered structure in the horizontal or vertical direction, thereby giving full play to the advantages of the filling medium 6 in mechanics and other aspects; the filling medium 6 has affinity for the pipe 1 and the optical side window 2 that are in contact with itself, and a variety of materials can increase the freedom of material selection for the filling medium 6. The affinity makes the filling medium 6 more closely combined with the pipe 1 and the optical side window 2, so that the filling medium 6 can better fill the gap between the optical element and the mounting frame, and will not break when processing the interface between the filling medium 6 and the pipe 1 and the optical side window 2, thereby improving the stability of the processing and making the conformal surface smoother after processing.

[0082] As described above, due to the existence of the stress relief structure of the limiting protrusion 3, sufficient processing allowance for the optical surface to be processed of the blank optical side window 2, and the filling effect of the fluid filling medium 6 and other factors that allow a certain error to exist, it is sufficient to process the side window positioning surface 10 of the blank optical side window 2 to a general accuracy in step 2, because even if there is a certain error in the side window positioning surface 10 of the blank optical side window 2, the shape and position accuracy of its optical surface after processing can be guaranteed.

[0083] Similarly, due to the existence of the stress relief structure of the limiting protrusion 3, the sufficient processing allowance left for the optical surface of the blank optical side window 2 to be processed, and the filling effect of the fluid filling medium 6 and other factors that allow a certain error to exist, when processing the pipe installation surface 9 on the pipe 1 for installing the blank optical side window 2 in step three, it is sufficient to process it to a general accuracy.

[0084] In order to make the filling medium 6 fully cover the pipe 1 and the rough optical side window 2, especially the junction between the conformal surface and the gap, so as to obtain a smooth and firm processing result, such as Figure 6 , Figure 8 and Fig.10 As shown in the cross-sectional structure of the conformal device to be processed, the grooves of the processed inner guide member 4 and the outer guide member 5 formed by the combination completely cover the gap formed by the pipe mounting surface 9 and the side window positioning surface 10, and appropriately span the pipe 1 and the blank optical side window 2, so that the injected filling medium 6 can extend to cover a portion of the pipe 1 and the blank optical side window 2.

[0085] In the case where the guide piece needs to be removed from the pipeline 1 to facilitate subsequent processing, its own material should be incompatible with the material of the filling medium 6, or a coating that is incompatible with the filling medium 6 should be applied to the surface of the guide piece before injecting the filling medium 6, or a film that is incompatible with the material of the filling medium 6 should be covered, so that the guide piece can be removed after the filling medium 6 solidifies and stabilizes, and the filling medium 6 will not be carried along during the removal of the guide piece, thereby damaging the conformal surface to be processed, which facilitates subsequent processing.

[0086] In order to further increase the strength of the filling medium 6, a mesh reinforcement structure can be added to the filling medium 6 in a timely manner. The mesh reinforcement structure can be a structure with weak rigidity, but it must have strong toughness. It is similar to tree roots in the soil or straw in mud bricks, which can make the filling medium 6 more solid and increase the overall toughness of the filling medium 6; it can also be a structure with strong rigidity to increase the overall rigidity of the filling medium 6. At the same time, the mesh reinforcement structure should be at a corresponding distance from the conformal surface to be processed, so as to prevent the mesh reinforcement structure from exposing the conformal surface after processing and destroying the flatness and smoothness of the conformal surface. Timely means that the mesh reinforcement structure can be added when the liquid filling medium 6 is prepared according to actual conditions, or the mesh reinforcement structure can be first placed in the cavity formed by the pipeline 1, the blank optical side window 2 and the guide piece before the filling medium 6 is injected, or the mesh reinforcement structure can be added after the filling medium 6 is injected, or at other appropriate times.

[0087] The conformal processing method proposed in the present invention adds a filling medium 6 between the optical side window 2 in a blank state and the pipe 1, and processes the optical side window 2, the pipe 1 and the filling medium 6 in a blank state together, while ensuring the shape and position accuracy of the optical side window 2, the gap of the conformal surface is eliminated to make the conformal surface flat and smooth, so that the processed optical side window 2 and the pipe 1 are truly integrated, and a stress relief structure is processed on the limiting protrusion 3 that limits the relative position of the optical side window 2, and sufficient processing allowance is reserved for the optical surface to be processed of the blank optical side window 2, and the filling medium 6 with fluidity is injected, so that all the installation and positioning surfaces of the optical side window 2, the pipe 1, the limiting protrusion 3 and other components that cooperate with each other only need to achieve general accuracy, thereby reducing the accuracy requirements for the optical side window 2, the pipe 1, the limiting protrusion 3 and other components during the processing, thereby reducing the processing difficulty.

[0088] This conformal processing method also effectively reduces the accuracy requirements of the optical side window 2, the pipeline 1 and other accessories before final finishing by integrally processing the optical side window 2 and the pipeline 1. The surface accuracy and position accuracy of the conformal surfaces of the optical side window 2 and the pipeline 1 can be completely reproduced by a high-precision machine tool through this processing method, avoiding the accumulation of errors caused by multiple clamping. At the same time, by using and processing parts whose material properties and spatial shape and size can match each other, the object being processed can produce thermal stress relief properties; and because the rigidity of the filling medium 6 is generally weaker than that of the optical side window 2 and the pipe 1, the optical side window 2 and the pipe 1 are connected to a certain degree of soft connection compared to themselves with the stress relief structure of the limiting protrusion 3, so the filling medium 6 and the limiting protrusion 3 can absorb the stress generated by temperature, pressure and impact vibration, so that the entire conformal device can adapt to changes in pressure and temperature and deformation caused by impact vibration, thereby improving the stability of the shape and position accuracy of the object being processed; at the same time, impact and vibration may also occur during the processing process, so this processing method can also effectively reduce the impact of impact and vibration that may occur during the processing on the device, thereby improving the reliability and yield of the processing. In short, this conformal processing method overcomes the problems of existing processing methods such as gaps in the conformal surface, difficulty in directly obtaining high shape and position accuracy of optical elements, unstable performance of the processed device, and high processing difficulty due to high precision requirements for parts.

[0089] From the above analysis, it can be seen that during the processing, a fluid filling medium 6 is injected, a stress relief structure is processed on the limiting protrusion 3, a large processing allowance is reserved for the blank optical element, the blank optical element and the mounting frame and the filling medium 6 are processed as one body, and the optical element with predetermined material properties and the mounting frame are processed to the designed shape and size, etc. as a whole that cooperates with each other, thereby achieving the elimination of gaps, the reduction of the precision requirements for parts and components, the direct acquisition of the shape and position accuracy of the device, and the improvement of the adaptability of the processed conformal device to the working environment. Their functions cooperate with each other and cannot be divided or viewed in isolation.

[0090] For example, the processing method of processing a stress relief structure on the limiting protrusion 3 and injecting a fluid filling medium 6 reduces the precision requirements for the positioning and mounting surface of the blank optical element and allows the blank optical element to reserve a large amount of processing allowance, and the processing allowance reserved for the optical surface of the blank optical element also reduces the precision requirements for the limiting protrusion 3 and the mounting frame, and the processing method of processing a stress relief structure on the limiting protrusion 3 and injecting a fluid filling medium 6 also simultaneously achieves the effects of eliminating the gap and improving the adaptability of the conformal device to the working environment. For another example, the limiting protrusion 3 can be used as a reinforcing rib to reinforce and strengthen the filling medium 6, which has a positive effect on stabilizing the position of the optical element and absorbing the impact of the tool during the processing, and processing a stress relief structure on the limiting protrusion 3 can increase the contact area between the limiting protrusion 3 and the filling medium 6, which can further improve the reinforcement and strengthening effect of the limiting protrusion 3 on the filling medium 6, so that the filling medium 6 is more tightly combined as a whole and not easy to loosen, and then the filling medium 6 is easier to be processed into a flat, smooth and firm conformal surface.

[0091] It is particularly noted that the pipeline conformal device in the embodiment originally only needs to be processed on the surface of the pipe body, but in order to introduce the present invention more comprehensively through more complex processing requirements, a double-sided conformal processing solution is provided in the illustration, that is, the conformal device can be processed on both sides, and the final effect is as follows: Fig.12 As shown, the limiting protrusion 3 and other structures have been completely covered by the filling medium 6. When only one side is used as the conformal surface, the shape and arrangement of the limiting protrusion 3, the optical side window 2, the pipe 1 and the filling medium 6 and the processing method can be adjusted according to actual needs with reference to the legend. The processing objects are not limited to pipes, but also include closed and non-closed conformal devices such as head covers. At the same time, the number and position of the optical side windows 2 can also be set according to actual needs, such as Fig.14The two optical elements shown are arranged relative to each other; the single-point diamond turning proposed in this embodiment is only one processing method, and other various methods can be selected to perform the corresponding process according to the shape of the workpiece and the material properties. In short, the simple change and adjustment of the processing method caused by the change of the type and structure of the conformal device does not deviate from the protection scope of the present invention. And the conformal processing method can also be used for other devices with similar characteristics.

[0092] The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

Claims

1. A conformal processing method, characterized in that: The following steps are involved: Step 1: Prepare the required parts and process them into a rough shape, leaving enough processing allowance for subsequent processes; Step 2: Processing a blank of the optical element, processing the positioning surface of the blank optical element to a required size, and leaving enough processing allowance for subsequent processing of the optical surface of the blank optical element; Step 3: Processing a mounting surface for mounting the rough optical element on the mounting frame, wherein the mounting space formed by the mounting surface is larger than the rough optical element to be mounted according to the design parameters; and processing or installing a limiting protrusion on the mounting surface, wherein the limiting protrusion does not protrude from the mounting frame on the side of the conformal surface to be processed and has a corresponding distance from the conformal surface to be processed, and a plurality of limiting protrusions can be arranged vertically and horizontally; Step 4: Install the processed guide piece on the corresponding side of the installation frame; Step 5: Install the processed rough optical element in the installation space formed by the installation surface processed on the installation frame, and determine the position of the rough optical element with the assistance of the limiting protrusion and the guide member, and after installation, a predetermined gap is left between the installation surface of the installation frame and the positioning surface corresponding to the rough optical element; Step 6: Inject a filling medium with a certain flow property into the cavity formed by the mounting frame, the rough optical element and the guide piece. After solidification, the filling medium can fill the predetermined gap between the mounting surface of the mounting frame and the positioning surface corresponding to the rough optical element, and has a certain strength and is convenient for subsequent processing. After the corresponding processing steps, a smooth, flat, firm and reliable surface can be formed; Step 7: After the filling medium to be injected solidifies and stabilizes, the guide piece is removed; Step 8: Clamp the mounting frame after removing the guide piece, the rough optical element and the filling medium together on a processing machine tool; Step nine, using a processing machine tool to process the shape-conserving device to be processed, which is composed of the mounting frame, the filling medium and the rough optical element; Step 10: Perform precision testing on the conformal device after processing. If the test fails, repeat the processing and testing steps until the test passes. The flow guide can be processed together with the mounting surface of the mounting frame as a part of the mounting frame in step three, and the flow guide is removed together with the mounting frame, the filling medium and the rough optical element in step nine; When multiple surfaces of the mounting frame and the rough optical element need to be processed conformally, other required flow guides are timely installed on the mounting frame and the corresponding positions of the rough optical element before the filling medium is injected; In the case where the guide member is mounted on the mounting frame, the guide member may be removed after the mounting frame, the blank optical element and the filling medium are clamped on the processing machine, or may not be removed but removed together with the processing of the mounting frame, the filling medium and the blank optical element; The measurement step can be cancelled if the measurement conditions are not met or the processing quality is controllable and reliable; In the case that the position of the blank optical element can be determined by the limiting protrusion, the guide member can be installed on the installation frame after the blank optical element is installed on the limiting protrusion.

2. A conformal processing method according to claim 1, characterized in that: A stress relief structure is processed on the limiting protrusion, and at least one stress relief direction of the stress relief structure is the same as the limiting direction of the limiting protrusion on the optical element.

3. A conformal processing method according to claim 2, characterized in that: When machining the limit protrusion, it is sufficient to machine it to general accuracy.

4. A conformal processing method according to claim 1, characterized in that: The optical element, the mounting frame and the limiting protrusion are processed to the designed size, so that the spatial size of the optical element, the mounting frame and the filling medium and the material properties cooperate with each other to produce the thermal stress relief property.

5. The conformal processing method according to claim 1, characterized in that: The filling medium injected in step six is ​​composed of one or more materials, and the filling medium can be injected in batches for multiple times. The filling medium has affinity to the mounting frame and optical elements in contact with itself.

6. A conformal processing method according to claim 1, characterized in that: In step 2, the positioning surface of the rough optical element may be machined to a general accuracy.

7. The conformal processing method according to claim 1, characterized in that: In step three, the mounting surface of the mounting frame for mounting the rough optical element may be machined to a general accuracy.

8. The conformal processing method according to claim 1, characterized in that: The groove formed by the guide itself or by combination completely covers the gap formed by the corresponding mounting surfaces and positioning surfaces of the mounting frame and the optical element, and spans the mounting frame and the optical element, so that the injected filler can extend to cover a portion of the mounting frame and the optical element.

9. The conformal processing method according to claim 1, characterized in that: When the guide piece needs to be removed from the mounting frame, a material that is incompatible with the filling medium is selected as the material of the guide piece, or a coating that is incompatible with the filling medium material is applied to the surface of the guide piece before injecting the filling medium, or a film that is incompatible with the filling medium material is covered.

10. The conformal processing method according to claim 1, characterized in that: A mesh reinforcement structure is added to the filling medium at an appropriate time, and the mesh reinforcement structure is at a corresponding distance from the conformal surface to be processed.

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