复合折射透镜（compound refractive lens, CRL）因具有结构紧凑、焦距可调、准直方便等优点，被用作硬X射线自由电子激光（X-ray free electron laser, XFEL）装置的光束聚焦器件。面向XFEL光束高精度聚焦对高性能CRL的实际需求，从CRL的几何结构设计原理出发，分析了不同材料CRL的性能参数，证明了单晶金刚石材料是适用于XFEL光束聚焦的CRL优选材料。同时，考虑超硬金刚石材料的难加工特性以及低重频钛宝石飞秒激光不能实现大厚度材料高效加工的实际问题，探索了高重频光纤飞秒激光对大厚度单晶金刚石材料进行高效加工的可行性。研究结果表明，高重频飞秒激光精密加工技术是实现金刚石CRL制备的有效手段。

Overview: Driven by the rapid development of national optical projects such as laser nuclear fusion and aerospace telescopes, as well as high-end civilian fields such as advanced instruments and optical lenses, the requirements for full-frequency domain processing errors and surfaces of optical components are becoming more and more stringent. At this stage, the optical components generally need to go through rough grinding, fine grinding, polishing and coating, and other processes, and their surface quality mainly depends on the defect removal ability and error control level of the polishing process. Whether the fine grinding process can obtain better surface shape accuracy and low surface/subsurface damage suppression determines the processing efficiency, and the ultra-precision processing manufacturing equipment is the premise of the realization of ultra-precision machining of the optical components. So far, all countries in the world have invested in the research and development of optical ultra-precision grinding and polishing technology, and have developed more relatively mature high-precision grinding and polishing equipment, which can better meet the processing needs of most of the current optical components. For the core equipment and key technologies required for ultra-precision manufacturing, China has long relied on imports. In order to break through the bottleneck restricting the development of ultra-precision technology in China at this stage, under the traction and drive of the national large-scale engineering project, China has made remarkable progress in optical ultra-precision manufacturing equipment and technology. However, for the optical ultra-precision technology and equipment, there is still a certain gap between China and the international advanced level, and it is necessary to continue to strengthen the research. In addition to the high-end grinding and polishing equipment necessary for the ultra-precision machining of optical components, it is also necessary to strengthen the technical level of a series of key supporting units, such as ultra-precision grinding and polishing processing technology, high-end key functional components, intelligent monitoring technology of processing environment, efficient ultra-precision machining tools, processing and inspection path planning and compensation processing strategies, computer-aided manufacturing and testing software, etc. The research, development, and application of these technologies are related to the development of high-end manufacturing in the civilian fields and national defense fields, and are also the focus of the country. This paper mainly focuses on the ultra-precision machining of large-diameter optical aspherical components. Starting from the grinding and polishing process route, this paper introduces the long-term research progress of the Precision Engineering Laboratory of Xiamen University in the field of large-diameter optical aspherical component processing, and introduces in detail the technical and system achievements such as ultra-precision grinding and polishing equipment, robot-assisted grinding and polishing, equipment intelligent monitoring system, processing technology and control software.

针对ITO玻璃表面线路激光刻蚀中因定位问题玻璃工件产生的微变形，采用微孔陶瓷对工件进行微气流阵列加压，确保高精度的激光刻蚀加工。分析不同加工工艺下的微气流压力分布，探究气流压力和刻蚀间隙对ITO玻璃刻蚀表面平面度的作用机制。结果表明：经微孔气流加压后，工件在气体流动的区域受到正压力，加工区域的压力分布较为均匀。由此可知，工件表面受到均布气压有利于刻蚀表面的定位，但过大的压力会导致工件微变形。实验结果显示：在合适的压力下，微孔气流加压可使得平面度低至8 μm，当压力在0.16~0.2 kPa，刻蚀间隙在1.8~1.9 mm时，工件表面压力为13.2~14.4 Pa，此时平面度最好，微米尺度的刻蚀线路清晰，不产生破损。最后，对微孔气流加压的ITO玻璃进行激光刻蚀加工，可得到8 μm以及25 μm的表面微细线路，解决了通常无微孔气流加压的刻蚀工艺导致局部断点或变形线路引起产品短路或开路等问题。

为研究BK7玻璃孔加工过程中出口破损的形成机理，本文在对破损形貌进行显微观测的基础上，基于断裂力学理论，分析了工件加工面所受载荷随裂纹扩展过程的演变规律及其对出口破损形成过程的影响；采用光滑质点流体动力学法对出口破损的形成过程进行了数值模拟，研究了出口破损的形成机理。结果表明：出口破损可分为初始裂纹区及扩展裂纹区，挤压载荷和弯矩的耦合作用驱使初始裂纹沿圆周方向扩展，显著增加了裂纹的倾斜角度和破损宽度，导致破损表面产生大量散射状条纹；借助光滑质点流体动力学法实现了对出口破损形成及脱落过程的数值模拟，发现初始裂纹贯穿整个未穿透厚度，刀具的瞬时切削力减小了78%；并且随着裂纹间歇性地沿圆周方向扩展，刀具切削力呈现出剧烈的周期性波动特征。