High-quality ultrasmooth surface is needed in modern optics, while the existing ultrasmooth surface processing methods are difficult to meet the requirement of the surface figure. In order to solve this problem, the active feed polishing (AFP) is taken as the research object, and the dual-rotor tool path is put forward for this technology. This tool path is generated based on the motion synthesis principle, which realizes smooth connection between different sections. At the same time, the eccentricity, the speed ratio, the velocity, and other parameters can be modified easily, avoiding using the complicated dual-rotor polishing mechanism. In order to further analyze the removal error, the removal amount calculation method for the dual-rotor path is researched and proposed. The simulation analysis results show that the greatest influence factor for the removal error is the sampling interval, the influence of the eccentricity and the speed ratio is less, and the velocity has little impact on it. In addition, the removal error can be controlled within acceptable range by reasonable selection of process parameters. Finally, through a processing experiment of a 100 mm plane lens, the feasibility and effectiveness of this path is verified. This experimental result shows that the AFP technology using the dual-rotor tool path can effectively correct the surface shape while reducing the surface roughness.
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