Tolerances
Tolerance is a critical factor impacting the performance
and cost of an optical system. Optical components usually
require much tighter tolerances than that commonly associated
with mechanical components
Cosmetic Surface Quality
Cosmetic surface quality describes the level of defects
that can be visually noted on the surface of an optical
component. The most common and widely accepted convention
for specifying surface quality is the U.S. Military Surface
Quality Specification, MIL-0-13830A. These standards include
scratches, digs, grayness, edge chips, and cemented interfaces.
scratch : A scratch is defined as any marking
or tearing of a polished optical surface. In principle,
scratch numbers refer to the width of the reference scratch
in ten thousandths of a millimeter.
Dig: A dig is a pit or small crater on
the polished optical surface. Digs are defined by their
diameters, which are the actual sizes of the digs in hundredths
of a millimeter. The sum of the diameters of all digs, as
estimated by the inspector, shall not exceed twice the diameter
of the maximum size specified per any 20mm diameter. Digs
less than 25 micrometers are ignored.
Edge Chips: Lens edge chips are allowed
only outside the clear aperture of the lens. The clear aperture
is 90% of the lens diameter unless otherwise specified.
Chips smaller than 0.5 mm are ignored, and those larger
than 0.5 mm are ground so that there is no shine to the
chip. The sum of the widths of chips larger than 0.5 mm
cannot exceed 30% of the lens perimeter. Prism edge chips
outside the clear aperture are allowed.
Cemented Interfaces: Because a cemented interface
is considered a lens surface, specified surface quality
standards apply. Edge separation at a cemented interface
cannot extend into the element more than half the distance
to the element clear aperture up to a maximum of 1.0 mm.
The sum of edge separations deeper than 0.5 mm cannot exceed
10% of the element perimeter.
Coating Defects: Defects caused by an optical
element coating, such as scratches, voids, pinholes, dust,
or stains, are considered with the Scratch-Dig specification
for that element. Coating defects are allowed if their size
is within the stated Scratch-Dig tolerance. Coating defects
are counted separately form substrate defects.
Surface Accuracy
When attempting to specify how closely an optical surface
conforms to its intended shape, a measure of surface accuracy
is needed. Surface accuracy can be determined by interferometric
techniques. Traditional techniques involve comparing the
actual surface to a test plate gage. In this approach, surface
accuracy is measured by counting the number of rings or
fringes and examining the regularity of the fringe. Modern
techniques for measuring surface accuracy utilize phase
measuring interferometry with advanced computer data analysis
software.
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Surface Flatness
Surface Fatness is simply surface accuracy with
respect to a plane reference surface and is specified in
terms of the wavelength f light, e.g. Lambda/2 at 633nm,
which represents the degree of power, with sometimes a form-error
addition, eg Lambda/5 at 633nm, which defines the allowed
irregularity of the fringe pattern. It is used extensively
in mirror and optical flat specifications.
Wavefront Error
Sometimes the best specification for an optical component
is its effect on the emergent wavefront. This is particularly
true for optical flats, collimation lenses, mirrors, and
retroreflectors where the presumed effect of the element
is to transmit or reflect the wavefront without changing
its shape. Wavefront distortion is often characterized by
the peak-to-valley deformation of the emergent wavefront
from its intended shape. Specifications are normally quoted
in fractions of a wavelength.
Centration
The mechanical axis and optical axis exactly coincide in
a perfectly centered lens. There are typically two types
of mounting configurations, edge mounting and surface mounting.
With edge mounting, the mechanical.
Parallelism
Parallelism of a window can be specified in terms of angle,
usually as minutes of arc. Sometimes it is in terms of thickness
variation or "run-out". With conventional polishing
techniques where no particular control of this parameter
is involved, parallelism of less than 10 to 20 arc minutes
can be expected. Where double-sided techniques are involved,
parallelisms obtained are usually not measurable by normal
methods. In some cases, to avoid multiple reflections between
the faces, a small wedge angle may actually be specified.
Other special requirements are upon customer design!
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